NISSAN PRIMERA model P11-144 series

Edition: May 2001 Revision: December 2001 (01) Publication No.: SM1A00-1P11E0E

QUICK REFERENCE INDEX

GENERAL INFORMATION

GI

MAINTENANCE

MA

ENGINE MECHANICAL

EM

PRIMERA

ENGINE LUBRICATION & COOLING SYSTEMS

LC

MODEL P11-144 SERIES

ENGINE CONTROL SYSTEM

QG16/18DE

ENGINE CONTROL SYSTEM

SR20DE

ENGINE CONTROL SYSTEM

CD20T

ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS

FE

CLUTCH

CL

MANUAL TRANSAXLE

MT

AUTOMATIC TRANSAXLE

AT

FRONT AXLE & FRONT SUSPENSION

FA

REAR AXLE & REAR SUSPENSION

RA

BRAKE SYSTEM

BR

STEERING SYSTEM

ST

RESTRAINT SYSTEM

RS

BODY & TRIM

BT

HEATER & AIR CONDITIONER

HA

ELECTRICAL SYSTEM

EL

ALPHABETICAL INDEX

IDX

NISSAN EUROPE N.V. © 2001 NISSAN EUROPE N.V. Produced in The Netherlands Not to be reproduced in whole or in part without the prior written permission of Nissan Europe N.V., Amsterdam, the Netherlands.

FOREWORD This manual contains maintenance and repair procedures for NISSAN PRIMERA, model P11-144 series. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

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

NISSAN EUROPE N.V. Service Operations Section Amsterdam, The Netherlands

GENERAL INFORMATION SECTION

GI

CONTENTS MODIFICATIONS ........................................................... 2 PRECAUTIONS ............................................................. 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for NATS ................................................ 3 Precautions for Super Lock System.......................... 4 General Precautions .................................................. 4 Precautions for Multiport Fuel Injection System or Engine Control Module.......................................... 6 Precautions for Three Way Catalyst.......................... 6 Precautions for Turbocharger .................................... 6 Precautions for Engine Oils....................................... 6 Precautions for Fuel .................................................. 7 Precautions for Air Conditioning ................................ 8 HOW TO USE THIS MANUAL...................................... 9 HOW TO READ WIRING DIAGRAMS.........................11 Sample/Wiring Diagram - EXAMPL - .......................11 Description ............................................................... 13 Wiring Diagram Codes (Cell Codes) ....................... 20 HOW TO CHECK TERMINAL..................................... 21 How to Probe Connectors ....................................... 21 How to Check Enlarged Contact Spring of Terminal ................................................................... 22 Waterproof Connector Inspection ............................ 23 Terminal Lock Inspection ......................................... 23

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ...................................... 24 Work Flow................................................................ 24 Incident Simulation Tests......................................... 25 Circuit Inspection ..................................................... 29 HOW TO FOLLOW TROUBLE DIAGNOSES ............ 35 How to Follow Test Groups in Trouble Diagnoses.. 35 CONSULT-II CHECKING SYSTEM ............................. 39 Function and System Application ............................ 39 Nickel Metal Hydride Battery Replacement............. 39 Checking Equipment................................................ 39 CONSULT-II Data Link Connector (DLC) Circuit .... 40 IDENTIFICATION INFORMATION............................... 41 Model Variation ........................................................ 41 Identification Number............................................... 43 Dimensions .............................................................. 45 Wheels and Tires..................................................... 45 LIFTING POINTS AND TOW TRUCK TOWING......... 46 Preparation .............................................................. 46 Board-on Lift ............................................................ 46 Garage Jack and Safety Stand ............................... 47 2-pole Lift ................................................................. 48 Tow Truck Towing .................................................... 49 TIGHTENING TORQUE OF STANDARD BOLTS ...... 50 ISO 15031-2 TERMINOLOGY LIST ............................ 51 ISO 15031-2 Terminology List ................................. 51

GI

MODIFICATIONS APPLIED FROM: SJN *** P11U 0526000 * : Any of the possibilities. See Vehicle Identification Number Arrangement.

OUTLINE OF MODIFICATIONS GENERAL ●

Various running changes on engine control system, electrical systems, body etc. Note that the introduction timing of some of the running changes may not be entirely in line with the above mentioned VIN.

●

For some running changes, the VIN (Vehicle Identification Number) is mentioned to specify the timing of the change implemention. The VIN No. may not be an exact number, there is an error range of approx. ±50 cars.

GI-2

PRECAUTIONS Observe the following precautions to ensure safe and proper servicing.

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pretensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). WARNING: ● To avoid rendering the SRS inoperative, (which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation) all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness), for easy identification.

Precautions for NATS NATS (Nissan Anti-Theft System)

SGI916

NATS will immobilize the engine if someone tries to start it without the registered key of NATS. Both of the originally supplied ignition key IDs have been NATS registered. The NATS security indicator is located on the instrument panel. The indicator flashes when the ignition switch is in “LOCK” or “Acc” position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. ● When NATS detects trouble, the malfunction indicator (MI) flashes. This flashing indicates that the anti-theft is not functioning, so prompt service is required. ● When servicing NATS (trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.

GI-3

PRECAUTIONS Precautions for NATS (Cont’d) Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT-II operation manual for NATS. Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. ● When servicing NATS (trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to obtain all keys from vehicle owner. A maximum of four key IDs can be registered into NATS.

Precautions for Super Lock System Locking the driver’s door or front passenger’s door with the key or remote control will lock all doors and activate the Super Lock System. The Super Lock System is designed to prevent theft as it can only be released when a front door is unlocked using a key or remote control. This means, none of the door locks can be operated from the inside using the door lock knob when the Super Lock System is activated.

General Precautions ●

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

●

Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

SGI285

●

SGI231

GI-4

PRECAUTIONS General Precautions (Cont’d) ●

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

●

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

●

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

●

Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as ECMs). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the fluids and lubricants specified in this manual. Use approved bonding agent, sealants or their equivalents when required. Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. Dispose of drained oil or solvent used for cleaning parts in an appropriate manner.

SEF289H

SGI233

Seat cover

Fender cover SGI234

● ● ● ●

● ● ● ● ● ●

GI-5

PRECAUTIONS Precautions for Multiport Fuel Injection System or Engine Control Module ●

● SGI787

●

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

Precautions for Three Way Catalyst If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions below: ● Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. ● When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. ● Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precautions for Turbocharger Cold engine

SGI292

The turbocharger turbine revolves at extremely high speeds and becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing through the turbocharger and to follow all required maintenance instructions and operating procedures. ● Always use the recommended oil. Follow the instructions for proper time to change the oil and proper oil level. ● Avoid accelerating engine to a high rpm immediately after starting. ● If engine had been operating at high rpm for an extended period of time, let it idle for a few minutes prior to shutting it off.

Precautions for Engine Oils Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS ●

Avoid prolonged and repeated contact with oils, particularly used engine oils.

GI-6

PRECAUTIONS Precautions for Engine Oils (Cont’d) ● ● ● ● ● ● ●

● ● ● ●

Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First Aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use gasoline, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practicable, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses. The regulations concerning the pollution of the environment will vary between regions.

Precautions for Fuel GASOLINE ENGINE: Unleaded gasoline of at least 95 octane (RON) CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the catalytic converter.

DIESEL ENGINE*: Diesel fuel of at least 50 cetane * If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions. ● Above −7°C (20°F) ... Summer type diesel fuel. ● Below −7°C (20°F) ... Winter type diesel fuel.

GI-7

PRECAUTIONS Precautions for Fuel (Cont’d) CAUTION: ● Do not use home heating oil, gasoline, or other alternate fuels in your diesel engine. The use of those can cause engine damage. ● Do not use summer fuel at temperatures below −7°C (20°F). Cold temperatures will cause wax to form in the fuel, as a result, it may prevent the engine from running smoothly. ● Do not add gasoline or other alternative fuels to diesel fuel.

Precautions for Air Conditioning Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section (“HFC134a (R134a) Service Procedure”, “SERVICE PROCEDURES”) for specific instructions.

GI-8

HOW TO USE THIS MANUAL ● ● ● ● ● ●

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for. A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by mating it to the section’s black tab. THE CONTENTS are listed on the first page of each section. THE TITLE is indicated on the upper portion of each page and shows the part or system. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. “BR-5”). THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (MICROFICHE) or (EURO)FAST system (E.g. SEC440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. “Example” SEC. 440 Pad retainer (Upper side) 54 - 64 (5.5 - 6.5, 40 - 47)

Main pin Torque member

to sliding portion

Pin boot

Inner shim

Copper washer 17 - 20 (1.7 - 2.0, 12 - 14)

Pad retainer (Lower side)

Brake hose

Outer shim Cylinder body Piston seal

Pad Dust seal Piston

Air bleeder 7 - 9 (0.7 - 0.9, 62 - 80) Pin bolt 22 - 31 (2.2 - 3.2, 16 - 23)

N·m (kg-m, ft-lb) N·m (kg-m, in-lb) SBR364AC

●

THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

GI-9

HOW TO USE THIS MANUAL The following SYMBOLS AND ABBREVIATIONS are used: : Tightening torque M/T : Should be lubricated with grease. A/T Unless otherwise indicated, use A/C recommended multi-purpose P/S grease. SST : Should be lubricated with oil. SAE : Sealing point : Checking point SMJ ATF : Always replace after every disasD1 sembly. D2 P : Apply petroleum jelly. p : Apply ATF. D3 ★ : Select with proper thickness. D4 ✩ : Adjustment is required. OD SDS : Service Data and Specifications 22 LH, RH : Left-Hand, Right-Hand 21 LHD, RHD : Left-Hand Drive, Right-Hand Drive 12 FR, RR : Front, Rear 11

●

,

●

● ● ●

: : : : : : : : : : : : : : : : :

Manual Transaxle/Transmission Automatic Transaxle/Transmission Air Conditioner Power Steering Special Service Tools Society of Automotive Engineers, Inc. Super Multiple Junction Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear

The UNITS given in this manual are primarily expressed as an SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” Tightening torque: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) TROUBLE DIAGNOSES are included in sections dealing with complicated components and systems. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

GI-10

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

For Description, refer to GI-13. BATTERY

Refer to optional splice.

JOINT CONNECTOR-1 To ELEXAMPL Preceding page Next page

To GIEXAMPL-04

SWITCH

DIODE

RELAY

POWER POSITION A

GND

MOTOR

POSITION B

SIGNAL UNIT

GND

MOTOR CONTROL MODULE

A/T models M/T models

.

REFER TO THE FOLLOWING M1 , E103 FUSE BLOCK Junction Box (J/B) M2 FUSE BLOCK Junction Box (J/B) E127 FUSE BLOCK Junction Box (J/B)

YGI001

GI-11

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

M/T models

A/T models

BATTERY

BATTERY

RELAY

RELAY

SGI858

GI-12

HOW TO READ WIRING DIAGRAMS Description Number

Item

1 p

Power condition

2 p

Fusible link

3 p

Fusible link/fuse location

4 p

Fuse

5 p

Current rating

6 p

Connectors

7 p

Optional splice

8 p

Splice

9 p

Page crossing

10 p

Common connector

11 p

Option abbreviation

12 p

Relay

13 p

Connectors

14 p

Wire color

15 p

Option description

16 p

Switch

17 p

Assembly parts

18 p

Cell code

Description ●

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

●

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

●

●

This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to EL section (“POWER SUPPLY ROUTING”).

● ●

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

●

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

●

This shows that connector E3 is female and connector M1 is male. The G/R wire is located in the 1A terminal of both connectors. Terminal number with an alphanumeric reference (1A, 5B, etc.) indicates that the connector is an SMJ connector.

● ●

●

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

●

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

●

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

● ●

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

●

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

●

This shows an internal representation of the relay. For details, refer to EL section (“STANDARDIZED RELAY”).

●

This shows that the connector is connected to the body or a terminal with bolt or nut.

●

This shows a code for the color of the wire. B = Black BR = Brown W = White OR = Orange R = Red P = Pink G = Green PU = Purple L = Blue GY = Gray Y = Yellow SB = Sky Blue LG = Light Green CH = Dark Brown DG = Dark Green When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe

●

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

●

This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

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

●

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

GI-13

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

Item

Description ●

19 p

Current flow arrow

20 p

System branch

●

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

●

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

●

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

21 p

Page crossing

22 p

Shielded line

●

The line enclosed by broken line circle shows shield wire.

23 p

Component box in wave line

●

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

24 p

Component name

●

This shows the name of a component.

●

This shows the connector number. The letter shows which harness the connector is located in. Example: M: main harness. For details and to locate the connector, refer to EL section (“Main Harness”, “HARNESS LAYOUT”). A coordinate grid is included for complex harnesses to aid in locating connectors.

●

●

25 p

Connector number

26 p

Ground (GND)

27 p

Ground (GND)

28 p

Connector views

29 p

Common component

30 p

Connector color

31 p

Fusible link and fuse box

32 p

Reference area

●

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

●

This shows the ground connection.

●

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

●

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

●

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

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This shows the arrangement of fusible link(s) and fuse(s), used for connector views of “POWER SUPPLY ROUTING” in EL section. The open square shows current flow in, and the shaded square shows current flow out.

●

This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists on the foldout page.

GI-14

HOW TO READ WIRING DIAGRAMS Description (Cont’d) Example View from terminal side

CONNECTOR SYMBOLS Connector symbol

Single line Connector

View from harness side

Direction mark

Most of connector symbols in wiring diagrams are shown from the terminal side. ● Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark .

●

Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark .

●

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

Connector symbol

Double line Direction mark

Connector

SGI364

Example Male terminal

Guide

Connector

Connector symbol

Female terminal

Guide

Connector Connector symbol SGI363

GI-15

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

Example: Harness indication

● BCM connector

Single line

Connector numbers that indicate the harness side are enclosed by a single line. Connector numbers that indicate components are enclosed by a double line.

Component indication

A/C mode switch connector

Double line

SGI940

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

Normally open

Normally closed

SGI860

GI-16

HOW TO READ WIRING DIAGRAMS Description (Cont’d) DETECTABLE LINES AND NON-DETECTABLE LINES IGNITION SWITCH ON or START

VEHICLE SPEED SENSOR

SPEED OMETER M27

In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. ● A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM (Engine Control Module) can detect its malfunctions with the on-board diagnostic system. ● A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on-board diagnostic system.

Detectable line for DTC Non-detectable line for DTC

ECM (ENGINE CONTROL MODULE) SGI862

GI-17

HOW TO READ WIRING DIAGRAMS Description (Cont’d) MULTIPLE SWITCH The continuity of a multiple switch is described in two ways as shown below. ● The switch chart is used in schematic diagrams. ● The switch diagram is used in wiring diagrams. Example

(SWITCH CHART)

(SWITCH DIAGRAM)

WIPER SWITCH

INT

HI

INT

LO OFF

WASH

OFF

LO

HI WASH

WIPER SWITCH

Both switches are turned in combination

Continuity circuit of wiper switch SWITCH POSITION

CONTINUITY CIRCUIT

OFF INT LO HI WASH

SGI875

GI-18

HOW TO READ WIRING DIAGRAMS Description (Cont’d) REFERENCE AREA The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area. Example Super Multiple Junction (SMJ)

(Main harness)

(Engine room harness)

(Main harness)

(Engine room harness)

Connector Area Reference Area: Refer to the electrical reference pages at the end of the manual for the terminal arrangement of the connectors shown here in the “Reference Area”.

SGI092A

Super multiple junction (SMJ) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the manual.

GI-19

HOW TO READ WIRING DIAGRAMS Wiring Diagram Codes (Cell Codes) Use the chart below to find out what each wiring diagram code stands for. Code

Section

Wiring Diagram Name

Code

Section

Wiring Diagram Name

AAC/V

EC

IACV-AAC Valve

ILL

EL

Illumination

ABS ACL/SW

BR EC

Anti-lock Brake System Accelerator Position Switch

INJECT

EC

Injector

INT/L

EL

ADJRES

EC

Adjustment Resistor

A/C

HA

Manual Air Conditioner

KS

EC

Interior, Spot and Trunk Room Lamps Knock Sensor

A/CCUT ACC/SW

EC EC

Air Conditioner Cut Control Accelerator Switch (FC)

LOAD

EC

Load Signal

LKUP

EC

A/T

AT

Automatic Transmission

Torque Converter Clutch Solenoid Valve

AIM

EL

Headlamp Aiming Control

LOAD

EC

Load Signal

APS AIRREG AT/C AUDIO BACK/L BUZZER CHARGE CKPS CHIME CMPS COOL/F CSPS

EC EC EC EL EL EL EL EC EL EC EC EC

EC

MAIN

EC

METER

EL

MI MIRROR NATS NLS O2S

EC EL EL EC EC

PGC/V

EC

DTRL

EL

PLA PNP/SW POWER

EC EC EL

DEF D/LOCK

EL EL

PST/SW

EC

DTRL

EL

ECTS

EC

EGRC/V

EC

FCUT F/FOG FICD F/PUMP FTS GLOW GOVNR

EC EL EC EC EC EC EC

R/FOG SROOF SRS S/LOCK S/SIG START STOP/L

EL EL RS EL EC EL EL

TAIL/L

EL

TCV TPS

EC EC

TURN

EL

H/LAMP

EL

H/SEAT HEAT HLC HO2S HORN IATS IGN/SG

EL HA EL EC EL EC EC

Accelerator Position Sensor IACV-Air Regulator A/T Control Audio Back-up Lamp Warning Buzzer Charging System Crankshaft Position Sensor Warning Chime Camshaft Position Sensor Cooling Fan Control Control Sleeve Position Sensor Headlamp — With Daytime Light System Rear Window Defogger Power Door Lock Headlamp — With Daytime Light System Engine Coolant Temperature Sensor EGR and canister Control Solenoid Valve Fuel Cut Solenoid Valve Front Fog Lamp IACV-FICD Solenoid Valve Fuel Pump Fuel Temperature Sensor Quick-glow system Electric Governor Headlamp — Without Daytime Light System Heated Seat Heater Headlamp Washer Heated Oxygen Sensor Horn, Cigarette Lighter, Clock Intake Air Temperature Sensor Ignition Signal

MAFS

VSS VTC WARN WINDOW WIPER WIP/R

EC EC EL EL EL EL

Mass Air Flow Sensor Main Power Supply and Ground Circuit Speedometer, Tachometer, Temp. and Fuel Gauges Malfunction Indicator Door Mirror Nissan Anti-Theft System Needle Lift Sensor Oxygen Sensor EVAP Canister Purge Control Solenoid Valve Partial Load Advance Control Park/Neutral Position Switch Power Supply Routing Power Steering Oil Pressure Switch Rear Fog Lamp Sun Roof Supplemental Restraint System Power Door Lock — Super Lock Start Signal Starting System Stop Lamp Clearance, License, and Tail Lamps Injection Timing Control Valve Throttle Position Sensor Turn Signal and Hazard Warning Lamps Vehicle Speed Sensor VTC Solenoid Valve Warning Lamps Power Window Front Wiper and Washer Rear Wiper and Washer

GI-20

HOW TO CHECK TERMINAL How to Probe Connectors Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

PROBING FROM HARNESS SIDE

Connector

Alligator clip

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

DMM

“T” pin SGI841

PROBING FROM TERMINAL SIDE Female Terminal ● There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

“T” pin

Sectional view (Female)

SEL265V

●

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

Retainer

SEL266V

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

Sectional view (Male)

“T” pin

Male terminal

SEL267V

GI-21

HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal An enlarged contact spring of a terminal may create intermittent signals in the circuit. If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal.

1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up. Male terminal

Wire

SEL270V

3. While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands. Do not apply force against the terminal.

SEL271V

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

SEL272V

●

OK

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

NG

SEL273V

GI-22

HOW TO CHECK TERMINAL Waterproof Connector Inspection

Wire seal

If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.

Connector housing

RUBBER SEAL INSPECTION ●

Rubber seal SEL275V

●

Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

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

Terminal Lock Inspection

Male connector Female connector

Locked terminal

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

Intermittent contact Unlocked terminal SEL330V

GI-23

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Work Flow

START

LISTEN TO CUSTOMER COMPLAINTS

STEP 1

VERIFY THE SYMPTOM

STEP 2 SYMPTOM SIMULATION

NARROW THE POSSIBLE CAUSE

STEP 3

INSPECT THE CIRCUIT

STEP 4

REPAIR THE CIRCUIT

STEP 5

STEP 6

MAKE SURE THE CIRCUIT WORKS

END SGI838

STEP STEP 1

DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis: WHAT

Vehicle Model, Engine, Transmission and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

STEP 2

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

STEP 3

Get the proper diagnosis materials together including: POWER SUPPLY ROUTING System Operation Descriptions Applicable Service Manual Sections Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests INTRODUCTION Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics: ● Vehicle vibration ● Heat sensitive ● Freezing ● Water intrusion ● Electrical load ● Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the illustration below.

Connectors & harness Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection.

Hint Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system.

Sensors & relays Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay. Vibration test

Tap gently.

Shake gently. Bend gently.

GI-25

SGI839

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) Possible cause Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Intermittent signals through pierced insulation

Enlarged

Proper crimp

Normal

Insulation not removed

Wire strands missing

DEFORMED (ENLARGED) FEMALE TERMINALS DEFECTIVE INSULATION STRIPPING Male half Female half Seal

Locked terminal

Loose

Seal Unlocked terminal (Hidden by wire seal)

Intermittent contact

Check for unlocked terminals by pulling each wire at the end of the connector.

TERMINAL NOT PROPERLY SEATED SGI840

Tester probe

Connector

Alligator clip “T” pin

DMM SGI841

When probing a connector it is possible to enlarge the contact spring opening. If this occurs it may create an intermittent signal in the circuit. When probing a connector, use care not to enlarge the opening. The probe of the Digital Multimeter (DMM) may not fit into the connector cavity. In such cases make an extension of a “T” pin and probe it from the harness side of the connector. Most DMMs have accessory alligator clips. Slide these over the probe to allow clipping the “T” pin for a better contact. If you have any difficulty probing a terminal, inspect the terminal. Ensure you have not accidentally opened the contact spring or pulled a wire loose.

GI-26

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) Engine compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: ● ● ● ● ●

Connectors not fully seated. Wiring harness not long enough and is being stressed due to engine vibrations or rocking. Wires laying across brackets or moving components. Loose, dirty or corroded ground wires. Wires routed too close to hot components.

To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to GROUND INSPECTION described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity.

Behind the instrument panel An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw.

Under seating areas An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

HEAT SENSITIVE

Heating test

The owner’s problem may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. Do not heat components above 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component.

Heat gun

Do not heat above 60°C (140°F). SGI842

GI-27

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

Freezing test

Water in connector

Short

Solenoid SGI843

The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

WATER INTRUSION

Water intrusion test

The incident may occur only during high humidity or in rainy/ snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. Do not spray water directly on any electrical components.

SGI844

ELECTRICAL LOAD

Electrical load test

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

“ON”

COLD OR HOT START UP A/C

Rear window defogger

Light switch

SGI845

On some occasions an electrical incident may occur only when the car is started cold. Or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis.

GI-28

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection INTRODUCTION In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this.

OPEN

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

SHORT

There are two types of shorts. ●

SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

●

SHORT TO GROUND

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

TESTING FOR “OPENS” IN THE CIRCUIT Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system. Inspection for opens (Voltage check) DMM

FUSE BLOCK

N.C. RELAY

SOLENOID

SW1 OPEN A B+

SIDE

OPEN B

OPEN C DMM

DMM (Continuity check)

SW2 SGI846

Continuity check method The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (OL, no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits please refer to the schematic above. 1. 2. 3. 4.

Disconnect the battery negative cable. Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) Connect one probe of the DMM to the fuse block terminal on the load side. Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) 5. Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) 6. Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the above example.

GI-29

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Voltage check method To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. 1. Connect one probe of the DMM to a known good ground. 2. Begin probing at one end of the circuit and work your way to the other end. 3. With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. no voltage; open is between fuse block and SW1 (point A). 4. Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). 5. Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the above example.

TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system please refer to the schematic below. Inspection for shorts IGN “ON” OR “START”

(Resistance check) FUSE BLOCK

DMM

RELAY

SOLENOID

SW1 B+

SIDE SHORT A

SHORT B

DMM (Voltage check)

SW2

SHORT C SGI847

Resistance check method 1. Disconnect the battery negative cable and remove the blown fuse. 2. Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 3. Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a known good ground. 4. With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. 5. Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. 6. Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps.

GI-30

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Voltage check method 1. Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 2. Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse terminal (one lead on the B + terminal side of the fuse block and one lead on a known good ground). 3. With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. 4. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. 5. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: 1. Remove the ground bolt screw or clip. 2. Inspect all mating surfaces for tarnish, dirt, rust, etc. 3. Clean as required to assure good contact. 4. Reinstall bolt or screw securely. 5. Inspect for “add-on” accessories which may be interfering with the ground circuit. 6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. Ground Inspection

Remove bolt (screw).

Inspect mating surfaces for tarnish, dirt, rust, etc. Clean as required to assure good contact.

Reinstall bolt (screw) securely.

SGI853

GI-31

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) VOLTAGE DROP TESTS Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. Check the wire in the illustration. When measuring resistance with ohmmeter, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. Unwanted resistance can be caused by many situations as follows: Undersized wiring (single strand example) Corrosion on switch contacts Loose wire connections or splices. If repairs are needed always use wire that is of the same or larger gauge.

Measuring voltage drop — Accumulated method 1. Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of the voltmeter should be closer to power and the negative lead closer to ground. 2. Operate the circuit. 3. The voltmeter will indicate how many volts are being used to “push” current through that part of the circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. Symptom: Dim bulb or no operation 0 (zero) ohm resistance between switch and bulb DMM

Load Switch Power

Ground

Connection with high resistance

Battery

Ground

SGI848

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

GI-32

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 1. Connect the voltmeter as shown, starting at the battery and working your way around the circuit. 2. An unusually large voltage drop will indicate a component or wire that needs to be repaired. The illustration shows a poor connection causes a 4 volt drop. Switch

Battery Connection with high resistance

The chart that follows illustrates some maximum allowable voltage drops. These values are given as a guideline, the exact value for each component may vary. COMPONENT Wire Ground Connections Switch Contacts

VOLTAGE DROP Negligible <.001 volts Approx. 0.1 volts Approx. 0.3 volts

SGI854

GI-33

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) Relationship between open/short (high resistance) circuit and the ECM pin control System Description: When the switch is ON, the ECM lights up the lamp. Case 1 Switch FUSE

TERMINAL: 1 Monitoring of the switch operation (ON/OFF)

TERMINAL: 2 Power supply to light up the lamp

Lamp

Battery

Short: Open:

FUSE blows. Inoperative lamp

Short: FUSE blows when switch is ON. Open: Inoperative lamp

ECM

Short: Open:

Short & Open: Inoperative lamp

No problem Inoperative lamp

High resistance: (Single strand) See below.*

Input-output voltage chart Pin No.

Item

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

1

Switch

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Approx. 0

Approx. 0

Battery voltage

Approx. 0 (Inoperative lamp)

Approx. 0

Approx. 0

OFF 2

Lamp

Switch ON OFF

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

Case 2 Lamp FUSE

TERMINAL: 2 Monitoring of the switch operation (ON/OFF)

TERMINAL: 1 Ground control to light up the lamp

Switch

Battery

ECM Short: Open:

FUSE blows. Inoperative lamp

Short: Open:

Lamp stays ON. Inoperative lamp

Short: Lamp stays ON. (Same as the switch ON) Open: Inoperative lamp

Short: Open:

No problem Inoperative lamp

High resistance: See below. (Single strand)*

Input-output voltage chart Pin No.

Item

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

1

Lamp

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Battery voltage

Battery voltage

Approx. 0

Higher than 0 Approx. 4 (Example)

Approx. 5

Approx. 5

OFF 2

Switch

Switch ON OFF

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

SGI849-A

GI-34

HOW TO FOLLOW TROUBLE DIAGNOSES NOTICE Trouble diagnoses indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pinpoint Check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be in the “LOCK” position. 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnoses Example Type A

INSPECTION START

H

CHECK POWER SUPPLY. 1) Turn ignition switch to “ON” position. 2) Check voltage between terminal b and ground. p

NG

E

Check the following items. 1) Harness continuity between camshaft position sensor and battery 2) Engine relay-1 3) “BR” fusible link 4) Power source for ECM 5) Ignition switch

E

Check the following items. 1) Harness continuity between camshaft position sensor and ground 2) Ground circuit for ECM

Battery voltage should exist OK

H

CHECK GROUND CIRCUIT. 1) Turn ignition switch to “OFF” position. 2) Disconnect camshaft position sensor harness connector. 3) Check resistance between terminal p d and ground. Resistance:

NG

Approximately 0Ω H

OK SGI800-C

GI-35

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) HOW TO FOLLOW THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. CHECK POWER SUPPLY. 1) Turn ignition switch to “ON” position. 2) Check voltage between terminal b and ground. p Battery voltage should exist.

F

Check item being performed. Procedure, steps or measurement results

Measurement results Required results are indicated in bold type in the corresponding block, as shown below: These have the following meanings: Battery voltage → 11 - 14V or approximately 12V Voltage: Approximately 0V → Less than 1V

Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. indicated in the left upper portion of For example, symbol each illustration corresponds with the symbol in the flow chart for easy identification. More precisely, the procedure under the “CHECK POWER SUPPLY” outlined previously is indicated by an illustration .

Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol.

Direction mark Refer to “CONNECTOR SYMBOLS” on GI-15.

GI-36

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) Example Type B Example CHECK POWER SUPPLY CIRCUIT

CHECK GAUGE OPERATION

1. Turn ignition switch “ON”. 2. Check voltage between combination meter terminal 15 and ground. Battery voltage should exist.

1. Turn ignition switch “ON”. 2. Connect terminals B (Fuel), C (Temp.) and ground with wire for less than 10 seconds.

Fuel gauge Water temperature gauge

3. Check operation of gauge. Gauge should move smoothly to full scale. OK or NG

OK or NG OK NG

GO TO 2. Check the following. ● 10A fuse [No. 7, located in the fuse

block (J/B)]

OK

GO TO 4.

NG

Repair or replace gauge.

● Harness for open or short between

fuse and combination meter

CHECK GROUND CIRCUIT FOR GAUGES Check continuity between combination meter terminal 23 and ground. Continuity should exist.

CHECK GROUND CIRCUIT FOR FUEL TANK GAUGE UNIT Check harness continuity between fuel tank gauge unit terminal 2 and ground. Continuity should exist.

SGI975

1) Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. 2) Questions and required results. Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V 3) Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. For symbols, refer to “CONNECTOR SYMBOLS” (GI-15) and “Key to Symbols Signifying Measurements or Procedures” (GI-38). 4) Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.

GI-37

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses (Cont’d) Key to symbols signifying measurements or procedures Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector to be measured.

Procedure with CONSULT-II.

Check after connecting the connector to be measured.

Procedure without CONSULT-II.

Insert key into ignition switch.

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

Remove key from ignition switch.

Procedure without CONSULT-II or GST

Turn ignition switch to “LOCK” position.

A/C switch is “OFF”.

Turn ignition switch to “ON” position.

A/C switch is “ON”.

Turn ignition switch to “START” position.

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

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

Fan switch is “OFF”.

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

Apply positive voltage from battery with fuse directly to components.

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

Drive vehicle.

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

Disconnect battery negative cable.

Do not start engine, or check with engine stopped.

Depress brake pedal.

Start engine, or check with engine running.

Release brake pedal.

Apply parking brake.

Depress accelerator pedal.

Release parking brake.

Release accelerator pedal.

Check after engine is warmed up sufficiently.

Pin terminal check for SMJ type ECM and A/T control unit connectors. For details regarding the terminal arrangement, refer to the foldout page.

Voltage should be measured with a voltmeter. Circuit resistance should be measured with an ohmmeter. Current should be measured with an ammeter.

GI-38

CONSULT-II CHECKING SYSTEM Function and System Application Diagnostic test mode

Function

ENGINE

H⋅CVT

ABS

AIR BAG

NATS

Work support

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

×

—

—

—

—

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

×

x

x

×

×

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

—

—

—

x

—

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

—

—

—

×

—

Data monitor

Input/Output data in the ECM can be read.

×

x

x

—

—

DTC work support

This mode enables a technician to set operating conditions to confirm self-diagnosis status/results.

x

x

—

—

—

Active test

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

×

—

x

—

—

ECM part number

ECM part number can be read.

×

x

x

—

—

Control unit initialisation

All registered ignition key IDs in NATS components can be initialised and new IDs can be registered.

—

—

—

—

x

x

—

—

—

—

DTC & SRT confirma- The results of SRT (System Readiness Test) and the self-diagtion nosis status/results can be confirmed.

×: Applicable *1: NATS: Nissan Anti-Theft System

Nickel Metal Hydride Battery Replacement CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble of dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.

Checking Equipment When ordering the equipment below, contact your NISSAN distributor.

Tool name NISSAN CONSULT-II 1 CONSULT-II unit p and accessories 2 Program card p AED00B-1 and AEN00A (for NATS) Refer to the CONSULT-II operation manual to confirm the best combination of the tester internal software and the software mentioned above.

Description 1 p

2 p

NGI045

GI-39

CONSULT-II CHECKING SYSTEM Checking Equipment (Cont’d) NOTE: ● The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialisation) procedure. ● Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Data Link Connector (DLC) Circuit Example IGNITION SWITCH ON or START

ECM

AIR BAG DIAGNOSIS SENSOR UNIT

DATA LINK CONNECTOR (DLC-II FOR CONSULT-II AND GST)

To each diagnosed system : DDL2 communication line (J1962)

SGI084A

INSPECTION PROCEDURE If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom

Check item

CONSULT-II cannot access ● CONSULT-II DLC power supply circuit (Terminal 9) and ground circuit (Terminal 13) any system. (For detailed circuit, refer to “MIL & Data Link Connectors Wiring Diagram” in EC section.) ● CONSULT-II DDL cable CONSULT-II cannot access ● CONSULT-II program card (Check the appropriate CONSULT-II program card for the sysindividual system. (Other tem.) systems can be accessed.) ● Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.) ● Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring diagram for each system.)

GI-40

IDENTIFICATION INFORMATION Model Variation Body

Engine

Transaxle

QG16DE

RS5F70A

QG18DE

Grade

RHD

LHD

Low

BDGARBF-EEA

BDGALBF-EGA

High

BDGARUF-EEA

BDGALUF-EGA

Low

BATARBF-EEA

BATALBF-EGA

RS5F70A High

BATARUF-EEA

BATALUF-EGA

Low

BBYARBF-EEA

BBYALBF-EGA

High

BBYARUF-EEA

BBYALUF-EGA

Low

BBYARBZ-EEA

BBYALBZ-EGA

High

BBYARUZ-EEA

BBYALUZ-EGA

High

BBYARUW-EEA

BBYALUW-EGA

Low

BVCARBF-TEA

BVCALBF-TGA

High

BVCARUF-TEA

BVCALUF-TGA

Low

FDGARBF-EEA

FDGALBF-EGA

High

FDGARUF-EEA

FDGALUF-EGA

RS5F70A 4 Door SR20DE RE0F06A RE0F06A (M6) CD20T

QG16DE

QG18DE

RS5F32A

RS5F70A Low

FATARBF-EEA

FATALBF-EGA

High

FATARUF-EEA

FATALUF-EGA

Low

FBYARBF-EEA

FBYALBF-EGA

High

FBYARUF-EEA

FBYALUF-EGA

Low

FBYARBZ-EEA

FBYALBZ-EGA

RS5F70A

RS5F70A 5 Door SR20DE RE0F06A RE0F06A (M6) CD20T

QG18DE

High

FBYARUZ-EEA

FBYALUZ-EGA

High

FBYARUW-EEA

FBYALUW-EGA

Low

FVCARBF-TEA

FVCALBF-TGA

High

FVCARUF-TEA

FVCALUF-TGA

Low

TATARBF-EEA

TATALBF-EGA

RS5F32A

RS5F70A High

TATARUF-EEA

TATALUF-EGA

Low

TBYARBF-EEA

TBYALBF-EGA

High

TBYARUF-EEA

TBYALUF-EGA

Low

TBYARBZ-EEA

TBYALBZ-EGA

High

TBYARUZ-EEA

TBYALUZ-EGA

High

TBYARUW-EEA

TBYALUW-EGA

Low

TVCARBF-TEA

TVCALBF-TGA

High

TVCARUF-TEA

TVCALUF-TGA

RS5F70A WAGON

SR20DE RE0F06A RE0F06A (M6) CD20T

RS5F32A

GI-41

IDENTIFICATION INFORMATION Model Variation (Cont’d) Prefix and suffix designations: B

DG

A

L

B

F

P11

E

G

A A: Standard

E: RHD models G: LHD models E: EGI T: Turbo (CD20T) Model F: 5-speed manual transaxle Z: H-CVT W: H-CVT (M6) B: LOW U: HIGH L: Left-hand drive R: Right-hand drive A: 2-wheel drive models DG: QG16DE engine AT: QG18DE engine BY: SR20DE engine VC: CD20T engine B: 4-door Sedan F: 5-door Hatchback T: Wagon

GI-42

IDENTIFICATION INFORMATION Identification Number

Vehicle identification number Vehicle identification plate Air conditioner specification label

NGI046

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT For Europe SJN

B

F

A

P11

U

0

XXXXXX Vehicle serial number

0 : Stopgap (no meaning) Destination U : Europe Model A : 2-wheel drive Engine type F : QG16DE engine E : QG18DE engine C : SR20DE engine D : CD20T engine Body type B : 4-door Sedan F : 5-door Hatchback T: Wagon Manufacturer SJN : Nissan, Passenger vehicle

GI-43

IDENTIFICATION INFORMATION Identification Number (Cont’d) IDENTIFICATION PLATE

A B C D E F G H I J

Type approval number Vehicle identification number (chassis number) Gross vehicle weight (GVW) Gross combination weight (GCW) Gross axle weight (Front) Gross axle weight (Rear) Vehicle type specification Body colour code Trim colour code Model

NGI011

ENGINE SERIAL NUMBER SR20DE engine

QG16DE/QG18DE engine

Front

CD20T engine

Front Front

MANUAL TRANSAXLE NUMBER

NGI060

H⋅CVT NUMBER

RS5F32A and RS5F70A

RE0F06A Transaxle type

NGI048

NGI061

GI-44

IDENTIFICATION INFORMATION Dimensions Unit: mm (in)

H/B & Sedan

Wagon

Overall length

4522 (178.03)

4566 (179.76)

Overall width

1715 (67.52) *1

1715 (67.52) *1

Overall height

1410 (55.51) *2

1410 (55.51) *2

Front tread

1470 (57.87)

1470 (57.87)

Rear tread

1450 (57.09)

1450 (57.09)

Wheelbase

2600 (102.36)

2600 (102.36)

*1: Without mirrors. *2: Without roof mounted antenna.

Wheels and Tires Steel Offset mm (in)

Road wheel Aluminum

Offset mm (in) Tire size

Conventional Spare

GI-45

15 x 6J 45 (1.77)

—

—

—

—

15 x 6J

15 x 6J

16 x 7J

45 (1.77)

45 (1.77)

45 (1.77)

185/65HR15 195/60VR15 195/60R15 205/50R16 Conventional

Conventional

Conventional

185/65 HR15

LIFTING POINTS AND TOW TRUCK TOWING Preparation SPECIAL SERVICE TOOLS Tool number Tool name

Description

LM4086-0200 Board on attachment

NT001

LM4519-0000 Safety stand attachment

NT002

Board-on Lift Front

Pantograph jack point

Attachment

Side sill

CAUTION: Make sure vehicle is empty when lifting. ● The board-on lift attachment (LM4086-0200) set at front end of vehicle should be set on the front of the sill under the front door opening. ● Position attachments at front and rear ends of board-on lift.

Attachment (SST. No. LM4086-0200) AGI016

GI-46

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

Note: Safety stand points are the same as pantograph jack points.

Safety stand points Use safety stand adapter as shown for stable support.

Fit the lower side sill into groove.

Attachment SST No. LM4519-0000

Safety stand NGI021

GI-47

LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.

Note: Lift-up points are the same as pantograph jack points.

Lift pad

Put the sill in the groove of the lift pad to prevent the sill from deforming. If the pad does not have a groove, prepare a suitable attachment with one.

Sill

NGI022

GI-48

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing CAUTION: ● All applicable local laws regarding the towing operation must be obeyed. ● It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. ● When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral position. NISSAN recommends that vehicle be towed with the driving (front) wheels off the ground as illustrated.

TOWING A H⋅CVT MODEL WITH FOUR WHEELS ON GROUND

SGI805

H⋅CVT model

Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 mph) Distance: Less than 65 km (40 miles) CAUTION: Never tow a H⋅CVT model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transaxle.

TOWING A H⋅CVT MODEL WITH REAR WHEELS RAISED (With front wheels on ground) Never tow a H⋅CVT model with rear wheels raised (with front wheels on ground) as this may cause serious and expensive damage to the transaxle. If it is necessary to tow it with rear wheels raised, always use a towing dolly under the front wheels. SGI806-A

TOWING POINT Always pull the cable straight out from the vehicle. Never pull on the hook at a sideways angle. CAUTION: Remove the front spoiler when towing the vehicle forward. Otherwise, the towing device may damage the front spoiler.

Removable towing hook

Towing hook

GI-49

NGI049

TIGHTENING TORQUE OF STANDARD BOLTS

Grade

4T

Bolt size

Pitch mm N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

M6

6.0

1.0

5.1

0.52

3.8

45.1

6.1

0.62

4.5

53.8

1.25

13

1.3

9

—

15

1.5

11

—

M8

8.0 1.0

13

1.3

9

—

16

1.6

12

—

1.5

25

2.5

18

—

29

3.0

22

—

1.25

25

2.6

19

—

30

3.1

22

—

1.75

42

4.3

31

—

51

5.2

38

—

1.25

46

4.7

34

—

56

5.7

41

—

M10

M12

7T

9T

Tightening torque (Without lubricant)

Bolt diameter* mm

Hexagon head bolt

Hexagon flange bolt

10.0

12.0

M14

14.0

1.5

74

7.5

54

—

88

9.0

65

—

M6

6.0

1.0

8.4

0.86

6.2

74.6

10

1.0

7

87

M8

8.0

M10

1.25

21

2.1

15

—

25

2.5

18

—

1.0

22

2.2

16

—

26

2.7

20

—

1.5

41

4.2

30

—

48

4.9

35

—

1.25

43

4.4

32

—

51

5.2

38

—

1.75

71

7.2

52

—

84

8.6

62

—

10.0

M12

12.0 1.25

77

7.9

57

—

92

9.4

68

—

M14

14.0

1.5

127

13.0

94

—

147

15.0

108

—

M6

6.0

1.0

12

1.2

9

—

15

1.5

11

—

1.25

29

3.0

22

—

35

3.6

26

—

M8

8.0 1.0

31

3.2

23

—

37

3.8

27

—

M10

M12 M14

1.5

59

6.0

43

—

70

7.1

51

—

1.25

62

6.3

46

—

74

7.5

54

—

1.75

98

10.0

72

—

118

12.0

87

—

1.25

108

11.0

80

—

137

14.0

101

—

1.5

177

18.0

130

—

206

21.0

152

—

10.0

12.0 14.0

1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. Grade

*: Nominal diameter

Mark

4T

............

4

7T

............

7

9T

............

9

M

6 üüüNominal diameter of bolt threads (Unit: mm)

üüüMetric screw threads

GI-50

ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. ***: Not applicable

NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Absolute pressure sensor

***

***

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

CL

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT-II

DLC for CONSULT-II

Diagnostic connector for CONSULT-II

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only EEPROM memory

***

Electronic ignition system

EI system

Ignition timing control

Engine control module

ECM

Engine control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister or Canister

EVAP canister or Canister

Canister

Evaporative emission canister purge control solenoid valve

EVAP canister purge control solenoid valve

Canister control solenoid valve

GI-51

ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable

NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Evaporative emission canister purge control valve

EVAP canister purge control valve

Canister purge cut valve

Evaporative emission canister vent control valve

EVAP canister vent control valve

***

Evaporative emission canister purge volume control valve

EVAP canister purge volume control valve

Canister purge control valve

Evaporative emission control system pressure sensor

EVAP control system pressure sensor

***

Evaporative emission shut valve

EVAP shut valve

Shutoff valve

Evaporative emission system

EVAP system

Evaporative emission control system

Exhaust gas recirculation valve

EGR valve

EGR valve

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

Exhaust gas recirculation temperature sensor EGR temperature sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air temperature sensor

IATS

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator

MI

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure/Barometric pressure switch solenoid valve

MAP/BARO switch solenoid valve

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

GI-52

ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable

NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

Neutral position switch

***

Neutral switch

Non-volatile random access memory

NVRAM

***

On-board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch

Periodic trap oxidizer system

PTOX system

***

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

ST

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

SC

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Tank fuel temperature sensor

***

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way+oxidation catalyst

TWC+OC

Catalyst

GI-53

ISO 15031-2 TERMINOLOGY LIST ISO 15031-2 Terminology List (Cont’d) ***: Not applicable

NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

TB

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Turbocharger

TC

Turbocharger

Vacuum cut valve

***

Vacuum control valve

Vacuum cut valve bypass valve

***

***

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

GI-54

MAINTENANCE SECTION

MA

CONTENTS PRECAUTIONS AND PREPARATION.......................... 3 Special Service Tools ................................................ 3 Commercial Service Tool........................................... 3 PRE-DELIVERY INSPECTION ITEMS.......................... 4 GENERAL MAINTENANCE .......................................... 5 PERIODIC MAINTENANCE .......................................... 6 Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) .......................... 6 Chassis and Body Maintenance................................ 7 Maintenance Schedule for Diesel Engines (Annual Mileage < 30,000 km/year) .......................... 8 Chassis and Body Maintenance................................ 9 Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year) .......... 10 Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year) .........................11 Chassis and Body Maintenance.............................. 12 Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) ........................ 13 Chassis and Body Maintenance.............................. 14 Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km) .................. 15 RECOMMENDED FLUIDS AND LUBRICANTS......... 16 Fluids and Lubricants .............................................. 16 SAE Viscosity Number ............................................ 17

QG ENGINE MAINTENANCE ............................................ 18 Checking Drive Belts ............................................... 18 Changing Engine Coolant........................................ 19 Checking Cooling System ....................................... 21 Checking Radiator Cap ........................................... 21 Checking Fuel Lines ................................................ 22

Changing Fuel Filter ................................................ 23 Changing Air Cleaner Filter ..................................... 23 Changing Engine Oil................................................ 24 Changing Engine Oil Filter ...................................... 24 Checking and Changing Spark Plugs ..................... 25 Checking Positive Crankcase Ventilation (PCV) System ..................................................................... 26 Checking Vacuum Hoses and Connections ............ 26 Checking EVAP Vapour Lines ................................. 26 Checking Front Heated Oxygen Sensor (HO2S) .... 27

SR20DE ENGINE MAINTENANCE ............................................ 28 Checking Drive Belts ............................................... 28 Changing Engine Coolant........................................ 29 Checking Cooling System ....................................... 31 Checking Fuel Lines ................................................ 33 Changing Fuel Filter ................................................ 33 Changing Air Cleaner Filter ..................................... 34 Changing Engine Oil................................................ 34 Changing Engine Oil Filter ...................................... 35 Checking and Changing Spark Plugs ..................... 35 Checking Ignition Leads .......................................... 36 Checking Positive Crankcase Ventilation (PCV) System ..................................................................... 36 Checking Vacuum Hoses and Connections ............ 37 Checking EVAP Vapor Lines ................................... 37 Checking Front Heated Oxygen Sensor (HO2S) .... 38

CD20T ENGINE MAINTENANCE ............................................ 39 Checking Drive Belts ............................................... 39 Changing Engine Coolant........................................ 40

MA

Checking Cooling System ....................................... 42 Checking Fuel Lines ................................................ 43 Checking and Replacing Fuel Filter and Draining Water ....................................................................... 43 Changing Air Cleaner Filter ..................................... 44 Changing Engine Oil................................................ 45 Changing Engine Oil Filter ...................................... 45 Checking Injection Nozzles ..................................... 46 Replacing Timing Belt.............................................. 47

Tire Rotation ............................................................ 53 Checking Steering Gear and Linkage ..................... 53 Checking Power Steering Fluid and Lines .............. 53 Lubricating Hood Latches, Locks and Hinges......... 54 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters............................................. 54 Checking Body Corrosion........................................ 55

QG SERVICE DATA AND SPECIFICATIONS (SDS) ........ 56 Engine Maintenance ................................................ 56

CHASSIS AND BODY MAINTENANCE ..................... 48 Checking Exhaust System....................................... 48 Checking Clutch Fluid Level and Leaks.................. 48 Checking Clutch System ......................................... 48 Checking M/T Oil ..................................................... 48 Changing M/T Oil..................................................... 49 Checking CVT Fluid Level....................................... 49 Changing CVT Fluid ................................................ 50 Checking Brake Fluid Level and Leaks................... 51 Checking Brake System .......................................... 51 Changing Brake Fluid .............................................. 51 Checking Brake Booster, Vacuum Hoses, Connections and Check Valve ................................ 51 Checking Disc Brake ............................................... 51 Balancing Wheels .................................................... 53

SR20DE SERVICE DATA AND SPECIFICATIONS (SDS) ........ 57 Engine Maintenance ................................................ 57

CD20T SERVICE DATA AND SPECIFICATIONS (SDS) ........ 58 Engine Maintenance ................................................ 58

SERVICE DATA AND SPECIFICATIONS (SDS) ........ 59 Chassis and Body Maintenance.............................. 59

MA-2

PRECAUTIONS AND PREPARATION Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number Tool name

Engine application

Description

KV10115800 Oil filter cap wrench 65 mm (2.56 in) dia.

QG

SR

CD

−

X

−

X

−

−

−

−

X

X

X

X

−

−

X

Removing oil filter

NT346

Removing oil filter

KV10105900 Oil filter cap wrench 15 faces, Inner span: 80 mm (3.15 in) (Face to opposite corner) NT555

99545R2500 (KV101060S0) Oil filter wrench

Removing oil filter 15 faces, Inner span: 92.5 mm (3.642 in) (Face to opposite corner) NT631

EG17650301 Radiator cap tester adapter

a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) NT564

KV119E0030 Nozzle holder socket

Removing and installing injection nozzle assembly

NT648

Commercial Service Tool Tool name

Engine application

Description

QG

SR

CD

X

X

−

Wrench with a magnet to hold spark plug

Spark plug wrench

16 mm (0.63 in) NT047

MA-3

PRE-DELIVERY INSPECTION ITEMS Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that necessary items other than those listed here be added, paying due regard to the conditions in each country. Perform applicable items on each model. Consult text of this section for specifications.

UNDER HOOD − engine off

UNDER BODY

Radiator coolant level and coolant hose connections for leaks Battery fluid level, specific gravity and conditions of battery terminals Drive belts tension Fuel filter for water or dust, fuel lines and connections for leaks Engine oil level and oil leaks Clutch and brake reservoir fluid level and fluid lines for leaks Windshield and rear window washer and headlamp cleaner reservoir fluid level Power steering reservoir fluid level and hose connections for leaks

Manual transmission/transaxle, transfer and differential gear oil level Brake and fuel lines and oil/fluid reservoirs for leaks Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts Tighten rear body bolts and nuts (Models with wooden bed only)

ROAD TEST Clutch operation Parking brake operation Service brake operation Automatic transmission/transaxle shift timing and kickdown Steering control and returnability Engine performance Squeaks and rattles

ON INSIDE AND OUTSIDE Remove front spring/strut spacer (If applicable) Operation of all instruments, gauges, lights and accessories Operation of horn(s), wiper and washer Steering lock for operation Check air conditioner for gas leaks Front and rear seats, and seat belts for operation All moldings, trims and fittings for fit and alignment All windows for operation and alignment Hood, trunk lid, door panels for fit and alignment Latches, keys and locks for operation Weatherstrips for adhesion and fit Headlamp aiming Tighten wheel nuts (Inc. inner nuts if applicable) Tire pressure (Inc. spare tire) Check front wheels for toe-in Install clock/voltmeter/room lamp fuse (If applicable) Install deodorizing filter to air purifier (If applicable) Remove wiper blade protectors (If applicable)

ENGINE OPERATING AND HOT Adjust idle mixture and speed (and ignition timing*1) Automatic transmission/transaxle fluid level Engine idling and stop knob operation (Diesel only)

FINAL INSPECTION Install necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps) Inspect for interior and exterior metal and paint damage Check for spare tire, jack, tools (wheel chock), and literature Wash, clean interior and exterior *1: Not required on models with a direct ignition system : Not applicable to this model.

MA-4

GENERAL MAINTENANCE General maintenance includes those items which should be checked during normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue functioning correctly. Owners can perform the checks and inspections themselves, or they can be carried out by a NISSAN dealer. Item

Reference pages

OUTSIDE THE VEHICLE The maintenance items listed here should be checked periodically, unless otherwise specified. Tires Check the pressure with a gauge weekly when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear.

−

Windshield wiper blades Check for cracks or wear if not functioning correctly.

−

Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door function correctly. Also ensure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch prevents the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check for lubrication more often.

MA-54

Tire rotation Tires should be rotated every 10,000 km (6,000 miles).

MA-53

INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle etc. Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other lights are all operating correctly and installed securely. Also check headlight aim.

−

Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are functioning correctly.

−

Steering wheel Check that it has the specified play. Check for changes in the steering operation, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in.)

−

Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage.

MA-54

UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically e. g. each time you check the engine oil or refuel. Windshield washer fluid Check that there is adequate fluid in the tank.

−

Engine coolant level Check the coolant level when the engine is cold.

−

Engine oil level Check the level after parking the vehicle (on level ground) and turning off the engine.

MA-24 / MA-34 / MA-45

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

MA-51 / MA-48

Battery Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines.

MA-5

−

PERIODIC MAINTENANCE Maintenance Schedule for Petrol Engines (Annual Mileage < 30,000 km/year) QG16DE/QG18DE/SR20DE engines Abbreviations:

R = Replace

I = Inspect: Correct or replace if necessary

[ ] = At the specified mileage only

MAINTENANCE OPERATION

MAINTENANCE INTERVAL

km × 1,000 Perform on a kilometer basis, but on (miles × 1,000) an annual basis when driving less than 15,000 km (9,000 miles) per year Months

15 (9) 12

30

45

60

75

90

105 120

(18) (27) (36) (45) (54) (63) (72) 24

36

48

60

72

84

96

Engine compartment and under vehicle

QG16DE/ QG18DE

SR20DE

Reference pages

Engine oil (Use recommended oil)*

R

R

R

R

R

R

R

R

MA-24

MA-34

Engine oil filter (Use NISSAN genuine part or equivalent)*

R

R

R

R

R

R

R

R

MA-24

MA-35

Drive belts

I

I

I

I

I

I

I

I

MA-18

MA-28

Cooling system

I

I

I

I

I

I

I

I

MA-21

MA-31

MA-19

MA-29

MA-23

MA-34

EM-92

—

Engine anti-freeze coolant (Use genuine NISSAN Anti-Freeze Coolant (L2N) or equivalent)

See NOTE (1)

Air cleaner filter*

R

Intake and exhaust valve clearance (Non HLA models)

See NOTE (2)

Fuel and vapour lines Spark plugs

(Conventional type)

I

I

I

I

MA-22/MA-26

MA-33/ MA-37

R

R

R

R

MA-25

MA-35

I

—

MA-36

R

MA-23

MA-33

MA-27, EC-QG-134/ EC-QG-173

MA-38, EC-SR-146/ EC-SR-182

MA-26

MA-36

Ignition leads

I

Fuel filter* Heated oxygen sensor* PCV system

R

See NOTE (3) I

I

I

I

NOTE: (1) First replace at 90,000 km (54,000 miles)/72 months, then every 60,000 km (36,000 miles)/48 months. (2) Periodic maintenance is not required for QG engine models. However, if valve noise increases, check valve clearance. (3) Perform only according to “Maintenance under severe driving conditions”. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-6

PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:

R = Replace age only

I = Inspect: Correct or replace if necessary

L = Lubricate

MAINTENANCE OPERATION

T = Tighten

[ ] = At the specified mile-

MAINTENANCE INTERVAL

Perform on a kilometer basis, but on an annual basis when driving less than 15,000 km (9,000 miles) in a year

km × 1,000

15

(miles × 1,000)

(9)

Months

12

30

45

60

75

90

105

120

(18) (27) (36) (45) (54) (63) (72) 24

36

48

60

72

84

96

Underhood and under vehicle

Reference pages

Headlamp aiming

I

I

I

I

I

I

I

I

EL-87

Wheel alignment (if necessary, balance & rotate wheels)

I

I

I

I

I

I

I

I

FA-6/RA-6 MA-53

Brake pads, rotors & other components*

I

I

I

I

I

I

I

I

MA-51

Foot brake, parking brake & clutch (for free play, stroke & operation)

I

I

I

I

I

I

I

I

BR-13/BR-48/CL-5

I

MA-51

I

MA-51/MA-48

R

BR-7

I

MA-53

Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)

I I

Brake fluid*

I

R

Power steering fluid and lines (for level and leaks) Air bag system

I

I

I

I

I

I I

R I

I

I

I

R I

I

I

See NOTE (1)

RS-11

Ventilation air filter*

R

R

R

R

HA-117

Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent)

I

I

I

I

I

I

I

I

MA-49

CVT fluid (for level and leaks or replace. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent)*

I

I

I

[R]

I

I

I

[R]

MA-50

Steering gear & linkage, axle & suspension, exhaust system* Body corrosion

I

See NOTE (2)

I

I

I

MA-53/FA-5/ RA-5/MA-48 MA-55

NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-7

PERIODIC MAINTENANCE Maintenance Schedule for Diesel Engines (Annual Mileage < 30,000 km/year) CD20T engine Abbreviations:

R = Replace

I = Inspect: Correct or replace if necessary

C = Clean

MAINTENANCE OPERATION

[ ] = At the specified mileage only

MAINTENANCE INTERVAL

km × 1,000 Perform on a kilometer basis, but on a semi-annual basis when driving less than (miles x 1,000) 20,000 km (12,000 miles) per year. Months

10

20

30

40

50

60

70

80

90 100 110 120

(6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) 6

12

18

24

30

36

42

48

54

60

66

72 CD20T Reference pages

Engine compartment and under vehicle Engine oil (Use recommended oil)*

R

R

R

R

R

R

R

R

R

R

R

R

MA-45

Engine oil filter (Use NISSAN genuine part or equivalent)*

R

R

R

R

R

R

R

R

R

R

R

R

MA-45

Drive belts

I

I

I

I

I

I

I

I

I

I

I

I

MA-39

Camshaft

[R]

EM-59

Injection pump

[R]

EM-59

Timing belts Cooling system Engine anti-freeze coolant (Use genuine NISSAN Anti-freeze Coolant (L2N) or equivalent)

I

I

I

I

I

See NOTE (1) R

Fuel lines

I

I

R

MA-44

I

MA-43

See NOTE (2)

Fuel filter

MA-42 MA-40

Air cleaner filter*

Injection nozzles

I

MA-46 R

R

R

MA-43

NOTE: (1) First replace at 80,000 km (48,000 miles)/48 months, then every 60,000 km (36,000 miles)/36 months. (2) If engine power decreases, black exhaust smoke is emitted or engine noise increases, inspect and if necessary, adjust the fuel injection nozzles starting pressure and spray pattern. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-8

PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:

R = Replace age only

I = Inspect: Correct or replace if necessary

L = Lubricate

MAINTENANCE OPERATION Perform on a kilometer basis, but on a semi-annual basis when driving less than 20,000 km (12,000 miles) per year

T = Tighten

[ ] = At the specified mile-

MAINTENANCE INTERVAL km × 1,000

10

(miles x 1,000)

(6)

Months

6

20

30

40

50

60

70

80

90

100 110 120

(12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) 12

18

24

30

36

42

48

54

60

66

72 Reference pages

Underhood and under vehicle Headlamp aiming

I

I

I

I

I

I

EL-87

Wheel alignment (if necessary, balance & rotate wheels)

I

I

I

I

I

I

FA-6/RA-6/ (MA-53)

Brake pads, rotors & other components*

I

I

I

I

I

I

MA-51

Foot brake, parking brake & clutch (for free play, stroke & operation)

I

I

I

I

I

I

BR-48/ BR-13/CL-5

I

MA-51

I

MA-51/ MA-48

R

BR-7

I

MA-53

Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)

I I

I

Brake fluid* I

I

I

I

R I

I

I

See NOTE (1)

RS-11

Ventilation air filter*

R

Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent)

I

Steering gear & linkage, axle & suspension, exhaust system* Body corrosion

I

R

Power steering fluid and lines (for level and leaks) Air bag system

I

R I I

See NOTE (2)

I

R I I

I

R

HA-117

I

MA-49

I

MA-53/FA-5/ RA-5/MA-48 MA-55

NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-9

PERIODIC MAINTENANCE Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year) The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. A B C D E

— — — — —

Driving under dusty conditions Driving repeatedly short distances Towing a trailer or caravan Extensive idling Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high — Driving in high humidity areas or in mountainous areas

F

Driving condition A B C D .

A .

A .

.

.

.

.

.

.

.

.

.

.

.

E .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

G — Driving in areas using salt or other corrosive materials H — Driving on rough and/or muddy roads or in the desert I — Driving with frequent use of braking or in mountainous areas J — Frequent off road use or driving in water K — Sustained high speed driving L — Low quality lubricants or fuel

Maintenance item .

.

.

.

.

.

.

.

.

.

.

L

.

.

.

.

.

.

.

.

C .

.

.

.

.

F

.

.

.

.

.

.

.

.

H .

.

.

.

.

.

.

.

.

.

Petrol models

Replace

Every 7,500 km (4,500 miles) or 6 months

Diesel models

Replace

Every 5,000 km (3,000 miles) or 3 months

Petrol models

Replace

Every 30,000 km (18,000 miles) or 24 months

Diesel models

Replace

Every 20,000 km (12,000 miles) or 12 months

Petrol models

Replace

Every 45,000 km (27,000 miles) or 36 months

Diesel models

Replace

Every 20,000 km (12,000 miles) or 12 months

Inspect

Every 30,000 km (18,000 miles) or 24 months

Petrol models

Replace

Every 15,000 km (9,000 miles) or 12 months

Diesel models

Replace

Every 20,000 km (12,000 miles) or 12 months

Petrol models

Replace

Every 15,000 km (9,000 miles) or 12 months

Diesel models

Replace

Every 20,000 km (12,000 miles) or 12 months

Replace

Every 30,000 km (18,000 miles)

Air cleaner filter

Fuel filter

Front/Rear Heated Oxygen Sensor

Ventilation air filter

Brake fluid

CVT fluid Petrol models

A .

.

.

C .

.

.

.

.

.

.

G H I

G H .

.

.

.

.

.

.

Maintenance interval

Engine oil & engine oil filter

Petrol models A .

Maintenance operation

Brake pads, rotors & other brake system components Petrol models

Inspect

Every 7,500 km (4,500 miles) or 6 months

Diesel models

Inspect

Every 10,000 km (6,000 miles) or 6 months

Steering gear & linkage, axle & suspension parts, exhaust system Petrol models

Inspect

Every 15,000 km (9,000 miles) or 12 months

Diesel models

Inspect

Every 20,000 km (12,000 miles) or 12 months

MA-10

PERIODIC MAINTENANCE Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year) QG16DE/QG18DE/SR20DE engines Abbreviations:

R = Replace

I = Inspect: Correct or replace if necessary

MAINTENANCE OPERATION Perform on a kilometer basis only.

MAINTENANCE INTERVAL km × 1,000

15

(miles x 1,000)

(9)

30

45

60

75

90

105 120

(18) (27) (36) (45) (54) (63) (72)

Engine compartment and under vehicle

QG16DE/ QG18DE

SR20DE

Reference pages

Engine oil (Use recommended oil)*

R

R

R

R

R

R

R

R

MA-24

MA-34

Engine oil filter (Use NISSAN genuine part or equivalent)*

R

R

R

R

R

R

R

R

MA-24

MA-35

Drive belts

I

I

I

I

I

I

I

I

MA-18

MA-28

I

MA-21

MA-31

MA-19

MA-29

MA-23

MA-34

EM-92

—

I

MA-22/ MA-26

MA-33/ MA-37

R

Cooling system

I

Engine anti-freeze coolant (Use genuine NISSAN AntiFreeze Coolant (L2N) or equivalent)

I

See NOTE (1)

Air cleaner filter*

R

Intake & exhaust valve clearance (Non HLA models)

R

See NOTE (2)

Fuel and vapour lines Spark plugs

I

I

MA-25

MA-35

Ignition leads

(Conventional type)

I

—

MA-36

Fuel filter*

R

MA-23

MA-33

Heated oxygen sensor* PCV system

R

R

R

EC-QG-134/ EC-SR-146/ EC-QG-173 EC-SR-182

See NOTE (3) I

PCV filter*

I R

I

I

MA-26

MA-36

R

—

—

NOTE: (1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). (2) Periodic maintenance is not required for QG engine models. However, if valve noise increases, check valve clearance. (3) Perform only according to “Maintenance under severe driving conditions”. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-11

PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:

R = Replace age only

I = Inspect: Correct or replace if necessary

L = Lubricate

MAINTENANCE OPERATION Perform on a kilometer basis only.

T = Tighten

[ ] = At the specified mile-

MAINTENANCE INTERVAL km × 1,000

15

30

45

60

75

90

105

120

(miles x 1,000)

(9)

(18)

(27)

(36)

(45)

(54)

(63)

(72) Reference pages

Underhood and under vehicle Headlamp aiming

I

I

I

I

EL-87

Wheel alignment (if necessary, balance & rotate wheels)

I

I

I

I

FA-6/RA-6/ (MA-53)

Brake pads, rotors & other components*

I

I

I

I

MA-51

I

BR-48/BR-13/ CL-5

I

MA-51

Foot brake, parking brake & clutch (for free play, stroke & operation)

I

Brake booster vacuum hoses, connections, check valve

I

I

Brake & clutch, systems and fluid (for level and leaks)

I

Brake fluid*

I

I

R

Power steering fluid and lines (for level and leaks) Air bag system

I

I

I

I

I

MA-51/MA-48

R

BR-7

I

MA-53

See NOTE (1)

RS-11

Ventilation air filter*

R

R

R

R

HA-117

Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent.)

I

I

I

I

MA-49

CVT fluid (for level and leaks or replace. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent)*

I

[R]

I

[R]

MA-50

Steering gear and linkage, axle & suspension, exhaust system* Body corrosion

See NOTE (2)

I

I

MA-53/FA-5/ RA-5/MA-48 MA-55

NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-12

PERIODIC MAINTENANCE Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) CD20T engine Abbreviations:

R = Replace

I = Inspect: Correct or replace if necessary

C = Clean

MAINTENANCE OPERATION Perform on a kilometer basis only.

MAINTENANCE INTERVAL km × 1,000

10

(miles x 1,000)

(6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) CD20T

20

30

40

50

60

70

80

90 100 110 120

Reference pages

Engine compartment and under vehicle Engine oil (Use recommended oil)*

R

R

R

R

R

R

R

R

R

R

R

R

MA-45

Engine oil filter (Use NISSAN genuine part or equivalent)*

R

R

R

R

R

R

R

R

R

R

R

R

MA-45

Drive belts

I

I

I

I

I

I

I

I

I

I

I

I

MA-39

Camshaft

R

MA-47

Injection pump

R

MA-47

Timing belts Cooling system Engine anti-freeze coolant (Use genuine NISSAN Anti-Freeze Coolant (L2N) or equivalent)

I

I

I

See NOTE (1)

Air cleaner filter* Fuel lines Injection nozzles

I

MA-40 R

R

I

I

See NOTE (2)

Fuel filter

MA-42

MA-44 MA-43 MA-46

R

R

MA-43

NOTE: (1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). (2) If engine power decreases, black exhaust smoke is emitted or engine noise increases, inspect and if necessary, adjust the fuel injection nozzles starting pressure and spray pattern. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-13

PERIODIC MAINTENANCE Chassis and Body Maintenance Abbreviations:

R = Replace

I = Inspect: Correct or replace if necessary

L = Lubricate

MAINTENANCE OPERATION Perform on a kilometer basis only.

T = Tighten

MAINTENANCE INTERVAL

km × 1,000

10

(miles x 1,000)

(6)

20

30

40

50

60

70

80

90

100 110 120

(12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) Reference pages

Underhood and under vehicle Headlamp aiming

I

I

I

I

EL-87

Wheel alignment (if necessary, balance & rotate wheels)

I

I

I

I

FA-6/RA-6/ (MA-53)

Brake pads, rotors & other components*

I

I

I

I

MA-51

Foot brake, parking brake & clutch (for free play, stroke & operation)

I

I

I

I

BR-13/BR-48/ CL-5

I

MA-51

I

MA-51/MA-48

R

BR-7

I

MA-53

Brake booster vacuum hoses, connections, check valve Brake & clutch, systems and fluid (for level and leaks)

I I

Brake fluid*

I

R

Power steering fluid and lines (for level and leaks) Air bag system

I

I

I

I

See NOTE (1)

RS-11

Ventilation air filter*

R

R

R

R

HA-117

Manual transmission oil (check for leakage. Use genuine NISSAN XZ gear oil or exact equivalent.)

I

I

I

I

MA-49

I

MA-53/FA-5/ RA-5/MA-48

Steering gear & linkage, axle & suspension, exhaust system* Body corrosion

I

See NOTE (2)

MA-55

NOTE: (1) Inspect after 10 years, then every 2 years. (2) Inspect once per year. * Maintenance items with “*” should be performed more frequently according to “Maintenance under severe driving conditions”.

MA-14

PERIODIC MAINTENANCE Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km) The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. A B C D E

— — — — —

Driving under dusty conditions Driving repeatedly short distances Towing a trailer or caravan Extensive idling Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high — Driving in high humidity areas or in mountainous areas

F

Driving condition A B C D .

A .

A .

A .

.

.

.

.

.

.

.

.

.

E .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

G — Driving in areas using salt or other corrosive materials H — Driving on rough and/or muddy roads or in the desert I — Driving with frequent use of braking or in mountainous areas J — Frequent off road use or driving in water K — Sustained high speed driving L — Low quality lubricants or fuel

Maintenance item .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

L

Petrol models

Replace

Every 7,500 km (4,500 miles)

Diesel models

Replace

Every 5,000 km (3,000 miles)

Petrol models

Replace

Every 30,000 km (18,000 miles)

Diesel models

Replace

Every 30,000 km (18,000 miles)

Petrol models

Replace

Every 45,000 km (27,000 miles)

Diesel models

Replace

Every 30,000 km (18,000 miles)

Replace

Every 30,000 km (18,000 miles)

Inspect

Every 60,000 km (36,000 miles)

Petrol models

Replace

Every 15,000 km (9,000 miles)

Diesel models

Replace

Every 15,000 km (9,000 miles)

Petrol models

Replace

Every 30,000 km (18,000 miles)

Diesel models

Replace

Every 30,000 km (18,000 miles)

Replace

Every 22,500 km (13,500 miles)

Air cleaner filter

Fuel filter

PCV filter

Front/Rear Heated Oxygen Sensor Petrol Models

A .

.

.

.

.

.

.

.

.

.

.

F

.

.

.

.

.

.

.

.

.

.

.

.

Maintenance interval

Engine oil & engine oil filter

QG16DE .

Maintenance operation

Ventilation air filter

Brake fluid

.

C .

.

.

.

H .

.

.

.

CVT fluid

A .

C .

.

.

G H I

.

.

.

Brake pads, rotors & other brake system components

Petrol models

.

.

.

.

.

.

G H .

.

.

.

Petrol models

Inspect

Every 15,000 km (9,000 miles)

Diesel models

Inspect

Every 15,000 km (9,000 miles)

Steering gear & linkage, axle & suspension parts, exhaust system Petrol models

Inspect

Every 30,000 km (18,000 miles)

Diesel models

Inspect

Every 30,000 km (18,000 miles)

MA-15

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants Capacity (Approximate)

Recommended fluids and lubricants

Liter

Imp measure

QG16DE/QG18DE

2.9

5-1/8 pts

SR20DE

3.7

6-1/2 pts

CD20T

5.0

8-3/4 pts

QG16DE/QG18DE

2.7

4-3/4 pts

SR20DE

3.5

6-1/8 pts

CD20T

4.5

7-7/8 pts

QG16DE/QG18DE

6.1

10-3/4 pts

M/T

6.6

11-5/8 pts

CVT

6.8

12 pts

6.4

11-1/4 pts

0.8

1-3/8 pts

RS5F70A

3.0

5-1/4 pts

RS5F32A

3.6

6-3/8 pts

CVT fluid

8.1

14-1/8 pts

Power steering fluid

1.1

2 pts

Brake fluid

−

−

DOT 4 (US FMVSS No. 116)

Multi-purpose grease

−

−

NLGI No. 2 (Lithium soap base)

Engine oil (Refill)

With oil filter

Without oil filter

Cooling system (With reservoir tank)

SR20DE CD20T

Reservoir Manual transmission gear oil

Air conditioning system refrigerant

Petrol engines: API SH or SJ*/ACEA A2/96 Diesel engines: ACEA B2-96 (CCMC-PD2)*

Genuine NISSAN Anti-freeze Coolant (L2N) or equivalent.

Genuine NISSAN XZ gear oil or exact equivalent. Genuine NISSAN CVT fluid (NS-1) or exact equivalent Type DEXRONTM III or equivalent

R-134a compressor CR-14

NISSAN A/C System Oil Type R or exact equivalent

compressor CSV613

NISSAN A/C System Oil Type S or equivalent

Air conditioning system lubricants

*: For further details, see “SAE Viscosity Number”.

MA-16

RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number Outside Temperature Range Anticipated Before Next Oil Change

Outside Temperature Range Anticipated Before Next Oil Change PETROL ENGINE OIL

DIESEL ENGINE OIL

* Not recommended for sustained high speed driving

* Not recommended for sustained high speed driving

NTI035

●

●

TI0006

For warm and cold areas: 10W-30 is suitable. The use of 5W-30 can have a positive effect on fuel economy (ACEA A1-98). For hot areas: 20W-40 and 20W-50 are suitable.

●

●

●

MA-17

For cold and warm areas: 10W-30 is preferable for ambient temperatures above −20°C (−4°F). On turbocharger models, 5W-20 is not recommended, and 5W-30 should be used only below 0°C (32°F). For hot areas: 20W-40 and 20W-50 are suitable.

QG

ENGINE MAINTENANCE Checking Drive Belts

Lock bolt

.

Adjusting bolt .

16 - 21 (1.6 - 2.1, 12 - 15)

Alternator

Water pump pulley Power steering pump

Loosen

Idler pulley

Lock nut 6.3 - 8.3 (0.64 - 0.85, 56 - 74)

.

Adjusting bolt

Compressor

Loosen Crankshaft pulley Water pump pulley

With air conditioner

Alternator

Power steering pump .

Without air conditioner

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 왔 : Check point

Crankshaft pulley

NMA106

1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension. Deflection adjustment

Unit: mm (in)

Tension adjustment*

Used belt Limit

Unit: N (kg, lb)

Used belt New belt

After adjustment

Limit

After adjustment

New belt

292 (29.8, 65.6)

652 - 740 (66.5 - 75.5, 146.6 - 166.4)

789 - 877 (80.5 - 89.7, 177.4 - 197.6)

196 (20.0, 44.1)

495 - 583 (50.5 - 59.5, 111.3 - 131.1)

603 - 691 (61.5 - 70.5, 135.6 - 155.3)

Alternator Without airconditioner compressor With airconditioner compressor Power steering oil pump Applied pushing force

10.2 (0.402)

6.5 - 7.0 5.5 - 6.1 (0.256 - 0.276) (0.217 - 0.240)

8.1 (0.319)

5.3 - 5.7 4.5 - 5.0 (0.209 - 0.224) (0.177 - 0.197)

10.8 (0.425)

6.6 - 7.5 6.0 - 6.6 (0.260 - 0.295) (0.236 - 0.260) 98 N (10 kg, 22 lb)

—

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

MA-18

ENGINE MAINTENANCE

QG

Changing Engine Coolant

Turn to HOT

WARNING: To avoid being scalded, never change the coolant when the engine is hot. — DRAINING ENGINE COOLANT — Heater 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”. Temperature control dial

NMA104

Semi-automatic air conditioning 1. Set air conditioning system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.

Temperature control

NMA103

Front .

Front

.

Lower radiator hose

.

.

Radiator cap

Loosen

2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.

NMA051

4. Remove cylinder block drain plug and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-21. Drain plug

Loosen

NMA001

Air relief plug

NMA107

MA-19

ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

QG

— REFILLING ENGINE COOLANT — 6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3
(2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, reinstall the plug. Air relief plug: : 7 - 8 N·m (0,7 - 0,8 kg-m, 5,1 - 5,8 ft-lb) Then pour coolant in again. ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank): Unit: (Imp qt)

QG16DE/QG18DE

6.1 (5-3/8)

8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap.

Radiator

SMA182B

MAX. MIN.

SMA412B

10. Run engine at 2,500 rpm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and wait until it cools down. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.

MA-20

ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

QG

— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from the air relief hole. Then reinstall air relief plug. Air relief plug : 7 - 8 N·m (0.7 - 0.8 kg-m, 5.1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower fan is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.

Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

Checking Radiator Cap

EG17650301

SLC613

Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)

MA-21

ENGINE MAINTENANCE Checking Radiator Cap (Cont’d) ●

QG

When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.

Pull the negative-pressure valve to open it. Check that it closes completely when released.

SMA871B

CHECKING COOLING SYSTEM FOR LEAKS Hose adapter

EG17650301

Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.

SMA990A

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

Fuel line

Fuel tank

SMA803A

3 (0.12)

Unit: mm (in)

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts.

28 (1.10) Fuel hose clamps 1.0 - 1.5 N·m (0.10 - 0.15 kg-m, 8.7 - 13.0 in-lb) MMA104A

MA-22

ENGINE MAINTENANCE

QG

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

With Consult II 1. Release fuel pressure using the following procedure. a. Start engine. b. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. c. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. d. Turn ignition switch “OFF”. PEF823K

.

SMA288C

WARNING: Use rubber gloves to prevent fuel from contacting the skin when removing fuel hoses and filter. 2. Loosen fuel hose clamps. 3. Replace fuel filter. ● Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. ● Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. ● When tightening fuel hose clamps, refer to “Checking Fuel Lines”, MA-22

Changing Air Cleaner Filter Viscous paper type Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.

.

NMA006

MA-23

QG

ENGINE MAINTENANCE Oil filler cap

Oil filter Drain plug

SMA672C

Changing Engine Oil WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil grade: API SH or SJ/ACEA A2/96 Viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Refill oil capacity (Approximate): Unit:
(Imp pts)

Drain and refill With oil filter change

2.9

Without oil filter change

2.7

Dry engine (engine overhaul)

3.0

CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● The refill oil capacity depends on oil temperature and drain time. Use these specifications as a reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.

5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level.

Refill oil to this “H” level. Do not overfill. SMA390C

Changing Engine Oil Filter 1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Clean the oil filter mounting surface on the cylinder block. Coat the rubber seal of the new oil filter with engine oil.

SMA010

MA-24

QG

ENGINE MAINTENANCE Changing Engine Oil Filter (Cont’d)

3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-24. ● Clean excess oil from engine. 2/3 turn

SMA229B

Checking and Changing Spark Plugs 1. Remove ignition coils.

.

Ignition coils

SEM870F

Wrench with a magnet to hold spark plug

2. Remove spark plugs with spark plug wrench. 3. Check insulator for cracks or chips, gasket for damage or deterioration and electrode for wear and burning. If excessively worn, replace with new spark plugs. Spark plug:

16 mm (0.63 in)

Make

SMA294A

CHAMPION

NGK

Standard type

RC10YCC4, RC10YC4

BKR5E-11

Hot type

RC12YCC4, RC12YC4

BKR4E-11

Cold type

RC7YCC4, RC7YC4

BKR6E-11

Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling may occur with the standard type spark plug such as: ● frequent engine starts ● low ambient temperatures The cold type spark plug is suitable when spark knock may occur with the standard type spark plug such as: ● extended highway driving ● frequent high engine revolution

Side electrode

Gap

4. Check spark plug gap. Gap: 1.0 - 1.1 mm (0.039 - 0.043 in) 5. Install spark plugs. Reinstall ignition coils. Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

SMA476

MA-25

ENGINE MAINTENANCE

QG

Checking Positive Crankcase Ventilation (PCV) System CHECKING PCV VALVE With engine running at idle, disconnect ventilation hose from PCV valve. If valve is working correctly, a hissing noise will be heard as air passes through it, and a strong vacuum should be felt immediately when a finger is placed over valve inlet. SMA048

CHECKING VENTILATION HOSES 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

Checking Vacuum Hoses and Connections Check vacuum hoses for leaks, cracks, damage, loose connections, chafing and deterioration. Refer to Vacuum Hose Drawing in EMISSION CONTROL OVERALL SYSTEM in EC section.

Checking EVAP Vapour Lines Vapor line

Purge line

1. Visually inspect vapor lines for leaks, cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EC section.

SMA275C

MA-26

QG

ENGINE MAINTENANCE Checking Front Heated Oxygen Sensor (HO2S) Checking procedure INSPECTION START 왔

Start engine and warm it up until water temperature indicator points to the middle of gauge. C2DMM06 왔

1. See “M/R F/C MNT” in “Data monitor” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under noload. 3. Maintaining engine at 2,000 rpm under no-load (engine is warmed up sufficiently.), check that the monitor fluctuates between “LEAN” and “RICH” more than 5 times during 10 seconds. 1 time RICH → LEAN → RICH 2 times RICH → LEAN → RICH → LEAN → RICH ...

Fuse box Data link connector

.

NEF125A NEF125A

왔

OK

왔

INSPECTION END

Malfunction indicator lamp SEF051PA

MA-27

NG

Check and adjustment should be made by referring to IDLE SPEED/IGNITION TIMING/ IDLE MIXTURE RATIO INSPECTION (BASIC SERVICE PROCEDURE) in EC section.

SR20DE

ENGINE MAINTENANCE Checking Drive Belts Adjusting bolt

Adjusting bolt

Loosen Loosen

Tighten

Tighten

16 - 22 (1.6 - 2.2,12 - 16)

Loosen

16 - 22 (1.6 - 2.2, 12 - 16) Water pump

Alternator

Water pump Alternator

Power steering oil pump Power steering oil pump Crankshaft pulley Crankshaft pulley

Compressor

: N·m (kg-m, ft-lb)

Without air conditioner

With air conditioner

SMA266C

1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension. Deflection adjustment

Unit: mm (in)

Tension adjustment*

Used belt Limit

After adjustment

New belt

12 - 13 (0.47 - 0.51)

8-9 (0.31 - 0.35)

Air conditioner compressor Power steering oil pump

Alternator

Applied pushing force

Unit: N (kg, lb)

Used belt Limit

After adjustment

7-8 (0.28 - 0.31)

264 (26.9, 59.3)

493 - 583 (50.3 - 59.5, 110.8 - 131.1)

9 (0.35)

5.5 - 6.5 (0.217 - 0.256)

4.5 - 5.5 (0.177 - 0.217)

304 (31.0, 68.3)

534 - 623 (54.5 - 63.5, 120.0 - 140.1)

12 (0.47)

8-9 (0.31 - 0.35)

7-8 (0.28 - 0.31)

264 (26.9, 59.3)

493 - 583 (50.3 - 59.5, 110.8 - 131.1)

98 N (10 kg, 22 lb)

New belt 11720 70J00

11720 70J05

603 - 691 (61.5 - 70.5, 135.6 - 155.3)

652 - 740 (66.5 - 75.5, 146.6 - 166.4)

11920 9F500

11920 9F505

652 - 740 (66.5 - 75.5, 146.6 - 166.4)

838 - 926 (85.5 - 94.5, 188 - 208)

603 - 691 (61.5 - 70.5, 135.6 - 155.3)

603 - 691 (61.5 - 70.5, 135.6 - 155.3)

—

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

MA-28

ENGINE MAINTENANCE Checking Drive Belts (Cont’d)

SR20DE

Alternator drive belt fitting place (Models without air conditioner) Alternator drive belt Crankshaft pulley

Engine front

Alternator drive belt

Engine front

Set a belt in both crankshaft and alternator pulleys as shown in the figure.

Alternator pulley SMA328C

Changing Engine Coolant

Turn to HOT

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

— DRAINING ENGINE COOLANT — 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”.

Temperature control dial NMA104

Semi-automatic air conditioning 1. Set air conditioner system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.

Temperature control

NMA103

Lower radiator hose

2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.

Remove .

SMA285C

MA-29

SR20DE

ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

.

.

4. Remove cylinder block drain plug on water pipe and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-31.

Remove

Radiator filler cap

NMA048

Drain plug

Remove Oil level gauge guide .

SMA269c

Loosen

NMA005

— REFILLING ENGINE COOLANT — 6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3
(2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, re-install the plug. Air relief plug: : 10 N·m (1.0 kg-m, 7 ft-lb) Then pour coolant in again ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank): Unit:
(Imp qt)

SR20DE

Radiator

SMA182B

MA-30

M/T

6.6 (5-7/8)

CVT

6.8 (6)

ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

MAX. MIN.

SMA412B

SR20DE

8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap. 10. Run engine at 2,500 prm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and cool it down. ● Cool down using a fan to reduce the time. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.

— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from air relief hole, then reinstall air relief plug. Air relief plug: : 7 - 8 N·m (0.7 - 0.8 kg-m, 5,1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower fan is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.

Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering.

MA-31

ENGINE MAINTENANCE Checking Cooling System (Cont’d)

SR20DE

1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CHECKING RADIATOR CAP

EG17650301

SLC613

Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) ● When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.

Pull the negative-pressure valve to open it. Check that it closes completely when released.

SMA871B

CHECKING COOLING SYSTEM FOR LEAKS Hose adapter

EG17650301

Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.

SMA990A

MA-32

ENGINE MAINTENANCE

SR20DE

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

Fuel line

Fuel tank

SMA803A

3 (0.12)

Unit: mm (in)

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts.

28 (1.10) Fuel hose clamps 1.0 - 1.5 N·m (0.10 - 0.15 kg-m, 8.7 - 13.0 in-lb) MMA104A

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

With Consult II 1. Release fuel pressure using the following procedure. a. Start engine. b. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero. c. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. d. Turn ignition switch “OFF”. PEF823K

WARNING: Use rubber gloves to prevent fuel from contacting the skin when removing fuel hoses and filter. 2. Loosen fuel hose clamps. 3. Replace fuel filter. ● Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. ● Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. .

SMA288C

MA-33

ENGINE MAINTENANCE

SR20DE

Changing Air Cleaner Filter Viscous paper type Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.

NMA006

Changing Engine Oil

SR20DE engine model

Oil filter

NMA039

WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil grade: API SH or SJ/ACEA A2/96 Viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Refill oil capacity (Approximate): Unit:
(Imp pts)

Drain and refill With oil filter change

3.7 (6 - 1/2)

Without oil filter change

3.5 (6 - 1/8)

Dry engine (engine overhaul)

3.9 (6 - 7/8)

CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● The refill oil capacity depends on oil temperature and drain time. Use these specifications as a reference only. Always use the dipstick to determine when the proper amount of oil is in the engine.

5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level. Overfill

Add

Normal range NDI021

MA-34

SR20DE

ENGINE MAINTENANCE .

Changing Engine Oil Filter

SR20DE engine model

1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot.

Loosen

.

KV10115800

NMA041

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

SMA010

3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-34. ● Clean excess oil from engine. 2/3 turn

SMA229B

OK

Checking and Changing Spark Plugs

NG

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

SMA273C

Wrench with a magnet to hold spark plug

2. Remove spark plugs with spark plug wrench. 3. Check insulator for cracks or chips, gasket for damage or deterioration and electrode for wear and burning. If excessively worn, replace with new spark plugs.

Spark plug 16 mm (0.63 in)

Make

NGK

Standard type

BKR6EY-11

Hot type

—

Cold type

—

SMA294A

MA-35

Side electrode

ENGINE MAINTENANCE Checking and Changing Spark Plugs (Cont’d)

SR20DE

4. Check spark plug gap. Gap: 1.0 - 1.1 mm (0.039 - 0.043 in)

Gap

SMA476

5. Install spark plugs. Reconnect ignition wires according to numbers indicated on them. Spark plug: : 20 - 29 N·m (2 - 3 kg-m, 14 - 22 ft-lb)

Checking Ignition Leads 1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires and check for intermittent breaks. Resistance: Cylinder No.

Resistance kΩ [at 25°C (77°F)]

1

Approximately 3.8

2

Approximately 3.5

3

Approximately 2.7

4

Approximately 2.4

SMA015A

For U.K. (Made by Bougicord) 4.48 - 6.72 kΩ/m (1.365 - 2.048 kΩ/ft) [at 25°C (77°F)] If it exceeds the limit, replace the ignition wire with a new one.

Checking Positive Crankcase Ventilation (PCV) System CHECKING PCV VALVE With engine running at idle, disconnect ventilation hose from PCV valve. If valve is working correctly, a hissing noise will be heard as air passes through it, and a strong vacuum should be felt immediately when a finger is placed over valve inlet. SMA048

MA-36

SR20DE ENGINE MAINTENANCE Checking Positive Crankcase Ventilation (PCV) System (Cont’d)

CHECKING VENTILATION HOSES 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

Checking Vacuum Hoses and Connections Check vacuum hoses for leaks, cracks, damage, loose connections, chafing and deterioration. Refer to Vacuum Hose Drawing in EMISSION CONTROL OVERALL SYSTEM in EC section.

Checking EVAP Vapor Lines Vapor line

Purge line

1. Visually inspect vapor lines for leaks, cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EC section.

SMA275C

MA-37

SR20DE

ENGINE MAINTENANCE

Checking Front Heated Oxygen Sensor (HO2S) Checking procedure INSPECTION START 왔

Start engine and warm up until water temperature indicator points to the middle of gauge. PEF054P 왔

1. See “M/R F/C MNT” in “Data monitor” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under noload. 3. Maintaining engine at 2,000 rpm under no-load (engine is warmed up sufficiently.), check that the monitor fluctuates between “LEAN” and “RICH” more than 5 times during 10 seconds. 1 time RICH → LEAN → RICH 2 times RICH → LEAN → RICH → LEAN → RICH ...

Fuse box Data link connector

.

NEF125A NEF125A

왔

OK

왔

INSPECTION END

Malfunction indicator lamp SEF051PA

MA-38

NG

Check and adjustment should be made by referring to IDLE SPEED/IGNITION TIMING/ IDLE MIXTURE RATIO INSPECTION (BASIC SERVICE PROCEDURE) in EC section.

CD20T

ENGINE MAINTENANCE Checking Drive Belts

SMA880C

1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspect drive belt deflection or tension when engine is cold. ● Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. ● Turn crankshaft two revolutions and recheck drive belt deflection or tension.

Deflection adjustment

Unit: mm (in)

Used belt

New belt

Limit

After adjustment

Generator

17 (0.67)

10.5 - 12.5 (0.413 - 0.492)

8.5 - 10.5 (0.335 - 0.413)

Air conditioner compressor

17 (0.67)

11.5 - 13.5 (0.453 - 0.531)

9.5 - 11.5 (0.374 - 0.453)

Power steering oil pump

8 (0.31)

5-7 (0.20 - 0.28)

4-6 (0.16 - 0.24)

Applied pushing force

98 N (10 kg, 22 lb)

MA-39

ENGINE MAINTENANCE

CD20T

Changing Engine Coolant

Turn to HOT

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

— DRAINING ENGINE COOLANT — Heater 1. Set heater system as follows to prevent coolant from remaining in the system. ● Move temperature control dial all the way to “HOT”.

Temperature control dial NMA104

Semi-automatic air conditioning 1. Set air conditioning system as follows to prevent coolant from remaining in the system. a. Turn ignition switch “ON” and enter a temperature of 32°C on the heater control. b. Wait 30 seconds before turning ignition switch “OFF”.

Temperature control

.

NMA103

Radiator lower hose

.

2. Disconnect lower radiator hose and remove radiator cap. 3. Remove reservoir tank, drain coolant, then clean reservoir tank. Install it temporarily. ● Be careful not to allow coolant to contact drive belts.

NLC040

4. Remove cylinder block drain plug and air relief plug. 5. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-41.

Drain plug (cylinder block)

NLC041

— REFILLING ENGINE COOLANT — Air bleeder

SMA353C

6. Install lower radiator hose, reservoir tank and tighten cylinder block drain plug securely. ● Apply sealant to the thread of the cylinder block drain plug. : 55 - 75 N·m (5.7 - 7.6 kg-m, 41 - 55 ft-lb) 7. Fill up radiator with coolant at the speed of less than 3
(2-5/8 Imp qt)/min. ● If coolant spills from the air relief hole without bubbles, install the plug and then pour coolant in again.

MA-40

CD20T

ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

Air relief plug: : 8 - 9 N·m (0.8 - 0.9 kg-m, 5.9 - 6.6 ft-lb) ● Use genuine NISSAN Anti-Freeze Coolant or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Coolant capacity (With reservoir tank):

Radiator

Unit:
(Imp qt)

CD20T

6.1 (5-3/8)

SMA182B

MAX. MIN.

SMA412B

8. Fill radiator and reservoir tank to specified level. 9. Start engine without installing radiator cap and warm it up at 2,000 rpm until radiator lower hose becomes hot. ● If coolant level becomes low, refill coolant until coolant level does not change. ● If coolant overflows radiator filler hole, install filler cap. 10. Run engine at 2,500 prm for 10 seconds and return to idle speed. ● Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 11. Stop engine and wait until it cools down. ● If necessary, refill radiator up to filler neck. 12. Refill reservoir tank to Max line with coolant. 13. Repeat steps 9 through 12 two or more times with radiator cap installed until coolant level no longer drops. 14. Check cooling system for leaks with engine running. 15. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control lever set at several positions between COOL and HOT. ● Sound may be noticeable at heater water cock. 16. If the sound is heard, bleed air from cooling system by repeating steps 9 through 12 until coolant level no longer drops.

— FLUSHING COOLING SYSTEM — 1. Open air relief plug. 2. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Air relief plug : 7 - 8 N·m (0.7 - 0.8 kg-m, 5.1 - 5.8 ft-lb) Fill radiator and reservoir tank with water and reinstall radiator cap. 3. Run engine and warm it up sufficiently. 4. Rev engine 2 or 3 times under no-load. ● Make sure that blower is “OFF”. 5. Stop engine and wait until it cools down. 6. Drain water. 7. Repeat steps 1 through 6 until clear water begins to drain from radiator.

MA-41

ENGINE MAINTENANCE

CD20T

Checking Cooling System CHECKING HOSES Check hoses for proper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward. 2 ● Use compressed air lower than 5 kg/cm and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CHECKING RADIATOR CAP

EG17650301

SLC613

Apply pressure to radiator cap with cap tester to see if it is satisfactory. Radiator cap relief pressure: Standard 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2, 14 - 17 psi) Limit 59 - 118 kPa (0.59 - 1.18 bar, 0.6 - 1.2 kg/cm2, 9 - 17 psi) ● When installing radiator cap to the tester, apply water or coolant to the radiator cap seal.

MA-42

ENGINE MAINTENANCE Checking Cooling System (Cont’d)

CD20T

Pull the negative-pressure valve to open it. Check that it closes completely when released.

SMA871B

CHECKING COOLING SYSTEM FOR LEAKS Hose adapter

EG17650301

Apply pressure to the cooling system with cap tester to check for leakage. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than the specified value may cause damage to radiator.

SMA990A

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

Fuel line

Fuel tank

SMA803A

Checking and Replacing Fuel Filter and Draining Water CHECKING FUEL FILTER Check fuel filter for fuel leakage, damage and other abnormal signs. Loosen Drain valve

SMA794C

REPLACING FUEL FILTER 1. Disconnect fuel filter sensor connector and drain fuel.

MA-43

CD20T ENGINE MAINTENANCE Checking and Replacing Fuel Filter and Draining Water (Cont’d) 2. Remove fuel filter, using a suitable tool.

SMA896A

3. Wipe clean fuel filter mounting surface on fuel filter bracket and smear a little fuel on rubber seal of fuel filter. 4. Screw fuel filter on until O-ring touches mounting surface, then tighten an additional 2/3 turn. Follow instructions on fuel filter. 5. Install fuel filter sensor to new fuel filter. 6. Bleed air from fuel line. 7. Start engine and check for leaks.

SMA010

Up and down

Loosen

Drain valve

DRAINING WATER 1. Set a container under fuel filter. 2. Loosen drain cock and drain water. Loosening drain cock 4 to 5 turns causes water to start draining. Do not remove drain cock by loosening it excessively. If water does not drain properly, move the priming pump up and down. 3. Bleed air.

MMA105A

FUEL SYSTEM AIR BLEEDING 1. Move priming pump up and down until there is suddenly more resistance in the movement. Then stop this action and start the engine. 2. If engine does not operate smoothly after being started, rev it two or three times. When refilling empty fuel tank, bleed air out of fuel system.

Up and down

SMA795C

Changing Air Cleaner Filter Air filter

.

Unfasten clamps to change air cleaner filter. The viscous paper type filter does not need cleaning.

SMA668B

MA-44

CD20T

ENGINE MAINTENANCE Changing Engine Oil

Engine oil drain plug

SMA418C

Oil filter cap

WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil specification and viscosity: ● ACEA B2-96 (CCMC-PD2) ● See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-16. Oil capacity (Approximately): Unit:
(Imp pts)

Engine oil level gauge

Drain and refill With oil filter change

5.0

Without oil filter change

4.5

Dry engine (engine overhaul)

5.1

.

SMA411C

Refill oil to this “H” level. Do not overfill. SMA822C

CAUTION: ● Be sure to clean drain plug and install with new washer. Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) ● The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine. 5. Warm up engine, and check area around drain plug and oil filter for oil leakage. 6. Stop engine. 7. Check oil level.

Changing Engine Oil Filter 1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as engine and engine oil are hot.

Engine oil filter

SMA412C

MA-45

ENGINE MAINTENANCE Changing Engine Oil Filter (Cont’d) .

CD20T

99545R2500 (KV101060S0)

NMA037

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

SMA010

3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to “Changing Engine Oil”, MA-45. ● Clean excess oil from engine. 2/3 turn

SMA229B

Injection nozzle assembly

Checking Injection Nozzles 1. Remove injection delivery tubes and fuel spill tube. 2. Remove nozzle assembly with S.S.T. KV119E0030. No. 1 cylinder nozzle assembly should not be disassembled as it is provided with a needle lift sensor.

SMA419C

WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to come into contact with your hand or body, and make sure that your eyes are properly protected. 3. Clean and check nozzles. 4. Install nozzle to injection nozzle tester and bleed air from flare nut.

EF791A

MA-46

ENGINE MAINTENANCE Checking Injection Nozzles (Cont’d)

CD20T

5. Check initial injection pressure by pumping tester handle slowly (one time per second). Injection pressure: 12,749 kPa (127.5 bar, 130 kg/cm2, 1,849 psi) ● Always check initial injection pressure before installing new nozzle.

SEF672A

6. Check fuel spray pattern by pumping tester handle quickly (4 or 6 times per second). a. If main spray angle is within 30 degrees as shown, injection nozzle is good. b. It is still normal even if a thin stream of spray deviates from main spray (pattern B).

SEF079S

7. If spray is not correct, clean injection nozzle tip or replace it. Refer to EC section for injection pressure adjustment, cleaning and replacement. 8. Install all injection nozzles with S.S.T. KV119E0030 and securely connect fuel spill hoses and delivery tubes. 9. Bleed air from fuel system and check for fuel leakage with engine running.

Replacing Timing Belt Refer to “TIMING BELT” in EM section.

MA-47

CHASSIS AND BODY MAINTENANCE Checking Exhaust System Check exhaust pipes, silencers and mountings are attached correctly and inspect for leaks, cracks, damage, loose connections, chafing or deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks If fluid level is very low, check clutch system for leaks.

.

SMA449C

Checking Clutch System HYDRAULIC TYPE Check fluid lines, operating cylinder & damper for leaks, cracks, damage, loose connections, chafing & deterioration.

NMA044

MECHANICAL TYPE Check cable and linkage for incorrect attachment, chafing, wear and deterioration.

SMA141A

Checking M/T Oil Check for oil leakage and oil level. Never start engine while checking oil level. Filler plug: : 25 - 34 N·m (2.6 - 3.4 kg-m, 19 - 25 ft-lb)

SMA065C

MA-48

CHASSIS AND BODY MAINTENANCE Checking M/T Oil (Cont’d) 3.7 - 5.0 (0.38 - 0.51, 33 - 44)

Speedometer pinion assembly O-ring

Check that oil is not leaking from transaxle or around it. ● Remove speedometer pinion and check oil level distance “L” as shown. Oil level (“L”): RS5F70A (QG16DE/QG18DE) 75.5 - 80.5 mm (2.97 - 3.17 in) RS5F70A (SR20DE) 56.5 - 61.0 mm (2.22 - 2.60 in) RS5F32A (CD20T) 57 - 62 mm (2.24 - 2.44 in) Use genuine NISSAN XZ gear oil or exact equivalent.

Ruler Transmission case

: N·m (kg-m, in-lb)

NMA045

Changing M/T Oil Oil capacity (reference values only): RS5F70A 3.0
(5-1/4 Imp pts) RS5F32A 3.6 - 3.8
(6-3/8 - 6-3/4 Imp pts) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Use genuine NISSAN XZ gear oil or exact equivalent. Drain plug SMA145A

Checking CVT Fluid Level 1. Check for fluid leakage.

SMA146B

MIN

MAX

MIN MAX

UMA036

2. Check fluid level. Fluid level should be check using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) after vehicle has been driven approximately 10 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using “HOT” range. a. Park vehicle on level surface and set parking brake. b. Start engine and then move selector lever through reach gear range, ending in “P”.

MA-49

CHASSIS AND BODY MAINTENANCE Checking CVT Fluid Level (Cont’d) c. d. e. f.

Check fluid level with engine idling. Remove dipstick and wipe it clean with lint-free paper. Re-insert dipstick into charging pipe as far as it will go. Remove dipstick and note reading. If level is at low side of either range, add fluid. Use genuine NISSAN CVT fluid (NS-1) or exact equivalent. CAUTION Do not overfill.

CAUTION: Firmly fix the dipstick using a lip attached to the fluid charging pipe. Stopper (when fixing) Stopper (when releasing) A/T fluid level gauge A/T fluid charging pipe

SMA051D

3. Check fluid condition. Check fluid for contamination. If fluid is very dark, smells burned or contains frictional material check operation of CVT. Refer to section AT for checking operation of CVT.

Check fluid for contamination. SMA853B

Changing CVT Fluid

Drain plug SMA294C

1. Warm up CVT fluid by driving the vehicle for 10 minutes. 2. Stop engine. 3. Drain CVT fluid from drain plug and refill with new CVT fluid. Always refill same volume compared with drained fluid. Oil capacity: 8.1
(14 - 1/4 Imp pt) Drain plug: : 23 - 27 N·m (2.4 - 2.8 kg-m, 17 - 20 ft-lb) Use genuine NISSAN CVT fluid (NS-1) or exact equivalent. 4. Run engine at idle speed for five minutes. 5. Jack up the front of the vehicle, and rotate front wheels by selecting “D” and depressing accelerator pedal slowly until 50 km/h (2 or 3 times). 6. Check fluid level and condition. Refer to “Checking CVT Fluid Level”. If fluid is still dirty, repeat step 2. throught 6.

MA-50

CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks If fluid level is extremely low, check brake system for leaks, and brake pads for wear.

SBR991

Checking Brake System Check brake fluid lines and parking brake cables for security, leaks, chafing, abrasion, deterioration, etc.

ABR159

Changing Brake Fluid

SBR992

1. Drain brake fluid from each air bleeder valve. 2. Refill until new brake fluid comes out from each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to section BR. ● Refill with recommended brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. ● Avoid skin contamination and ingestion.

Checking Brake Booster, Vacuum Hoses, Connections and Check Valve Check vacuum lines, connections and check valve for security, air tightness, chafing and deterioration.

SMA402A

Checking Disc Brake Check condition of disc brake components.

ROTOR

SMA260A

Check condition and thickness. CL25VBG: Standard thickness 22.0 mm (0.866 in) Minimum thickness 20.0 mm (0.787 in)

MA-51

CHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont’d) CL25VG: Standard thickness 22.0 mm (0.866 in) Minimum thickness 20.0 mm (0.787 in) CL9HG: Standard thickness 10.0 mm (0.394 in) Minimum thickness 9.0 mm (0.354 in) CL9HDG: Standard thickness 10.0 mm (0.394 in) Minimum thickness 9.0 mm (0.354 in)

CALIPER Check operation and for leakage.

SMA922A

PAD

SMA847B

Check for wear or damage. CL25VBG: Standard thickness 11.0 mm (0.433 in) Minimum thickness 2.0 mm (0.079 in) CL25VG: Standard thickness 11.0 mm (0.433 in) Minimum thickness 2.0 mm (0.079 in) CL9HG: Standard thickness 9.3 mm (0.366 in) Minimum thickness 2.0 mm (0.079 in) CL9HDG: Standard thickness 9.3 mm (0.366 in) Minimum thickness 2.0 mm (0.079 in)

MA-52

CHASSIS AND BODY MAINTENANCE Balancing Wheels Wheel balance (maximum allowable unbalance): 10 g (0.35 oz) at rim flange. Tire balance weight: 5 - 60 g (0.18 - 2.12 oz)

Tire Rotation Right front

●

Right rear Spare tire

Radial tire

Left front

Do not include the T-type or space saver spare tire when rotating the tires. Wheel nuts: : 98 - 118 N·m (10 - 12 kg-m, 72 - 87 ft-lb)

Left rear SMA785C

Checking Steering Gear and Linkage STEERING GEAR ● ●

STEERING LINKAGE

: Check grease leakage. : Check tightening torque.

● SMA316C

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

Checking Power Steering Fluid and Lines

OPEN .

HOT MAX

COLD MAX COLD MIN .

Front

Check gear housing and boots for security, damage or grease leakage. Check connection with steering column for security. : Refer to ST section.

HOT MIN

Check fluid level in reservoir with engine off. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 196°F). Use “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: ● Do not overfill. ● Recommended fluid is Automatic Transmission Fluid “DEXRONTM III” type.

NMA052

CHECKING LINES ● ●

Check lines for leaks, cracks, damage, loose connections, chafing and deterioration. Check rack boots for accumulation of power steering fluid.

SST575B

MA-53

CHASSIS AND BODY MAINTENANCE Lubricating Hood Latches, Locks and Hinges

: Greasing point

MMA106A

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters CAUTION: ● After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (i.e. guide rail set). Nissan recommends to replace all seat belt assemblies in use during a collision, unless not damaged and properly operating after minor collision. Also inspect seat belt assemblies not in use during a collision, and replace if damaged or improperly operating. ● If any component of seat belt assembly is questionable, do not repair. Replace as seat belt assembly. ● If webbing is cut, frayed, or damaged, replace belt assembly. ● Never oil tongue and buckle. ● Use a genuine seat belt assembly.

Check anchors for loose mounting.

Check belts for damage. Check retractor for smooth operation.

For seat belt pre-tensioner, refer to section RS.

Check functioning of buckles and tongues when buckled and released.

Anchor bolt 43 - 55 N·m (4.4 - 5.6 kg-m, 32 - 41 ft-lb)

MMA098A

MA-54

CHASSIS AND BODY MAINTENANCE Checking Body Corrosion Visually check body panels for corrosion, paint damage (scratches, chipping, rubbing, etc.) or damage to the anti-corrosion materials. In particular, check the following locations.

Hemmed panels Hood front end, door lower end, trunk lid rear end, etc.

Panel joint Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine compartment, etc.

Panel edge Trunk lid opening, sunroof opening, fender wheel-arch flange, fuel filler lid flange, around holes in panel, etc.

Parts contact Waist moulding, windshield moulding, bumper, etc.

Protectors Damage or condition of mudguard, fender protector, chipping protector, etc.

Anti-corrosion materials Damage or separation of anti-corrosion materials under the body.

Drain holes Condition of drain holes at door and side sill. When repairing corroded areas, refer to the Corrosion Repair Manual.

MA-55

QG

SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection and tension Deflection adjustment

Unit: mm (in)

Tension adjustment*

Used belt

Used belt New belt

After adjustment

Limit

Unit: N (kg, lb)

Limit

After adjustment

New belt

292 (29.8, 65.6)

652 - 740 (66.5 - 75.5, 146.6 - 166.4)

789 - 877 (80.5 - 89.7, 177.4 - 197.6)

196 (20.0, 44.1)

495 - 583 (50.5 - 59.5, 111.3 - 131.1)

603 - 691 (61.5 - 70.5, 135.6 - 155.3)

Alternator Without airconditioner compressor With airconditioner compressor Power steering oil pump

10.2 (0.402)

6.5 - 7.0 5.5 - 6.1 (0.256 - 0.276) (0.217 - 0.240)

8.1 (0.319)

5.3 - 5.7 4.5 - 5.0 (0.209 - 0.224) (0.177 - 0.197)

10.8 (0.425)

6.6 - 7.5 6.0 - 6.6 (0.260 - 0.295) (0.236 - 0.260)

Applied pushing force

98 N (10 kg, 22 lb)

—

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

Oil capacity (Refill capacity)

Unit:
(Imp pts)

Spark plug

With oil filter change

2.9 (5 - 1/8)

Make

Without oil filter change

2.7 (4 - 3/4)

Standard type

RC10YCC4 RC10YC4

BKR5E-11

Hot type

RC12YCC4 RC12YC4

BKR4E-11

Cold type

RC7YCC4 RC7YC4

BKR6E-11

Coolant capacity

CHAMPION

Unit:
(Imp pts)

With reservoir tank

6.1 (10 - 3/4)

Reservoir tank

0.8 (1 - 3/8)

Plug gap

MA-56

mm (in)

NGK

1.0 - 1.1 (0.039 - 0.043)

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection and tension Deflection adjustment

Unit: mm (in)

Tension adjustment*

Used belt

Alternator

Used belt

Limit

After adjustment

New belt

12 - 13 (0.47 - 0.51)

8-9 (0.31 - 0.35)

Air conditioner compressor Power steering oil pump

Unit: N (kg, lb) New belt

Limit

After adjustment

7-8 (0.28 - 0.31)

264 (26.9, 59.3)

493 - 583 (50.3 - 59.5, 110.8 - 131.1)

9 (0.35)

5.5 - 6.5 (0.217 0.256)

4.5 - 5.5 (0.177 0.217)

304 (31.0, 68.3)

534 - 623 (54.5 - 63.5, 120.0 - 140.1)

12 (0.47)

8-9 (0.31 - 0.35)

7-8 (0.28 - 0.31)

264 (26.9, 59.3)

603 - 691 603 - 691 493 - 583 (61.5 - 70.5, (61.5 - 70.5, (50.3 - 59.5, 110.8 - 131.1) 135.6 - 155.3) 135.6 - 155.3)

Applied pushing force

98 N (10 kg, 22 lb)

11720 70J00

11720 70J05

652 - 740 603 - 691 (66.5 - 75.5, (61.5 - 70.5, 135.6 - 155.3) 146.6 - 166.4) 11920 9F500

11920 9F505

652 - 740 (66.5 - 75.5, 146.6 - 166.4)

838 - 926 (85.5 - 94.5, 188 - 208)

—

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

Oil capacity (Refill capacity)

Unit:
(Imp pts)

Spark plug Make

With oil filter change

3.7 (6 - 1/2)

Without oil filter change

3.5 (6 - 1/8)

Type Standard

Coolant capacity (Refill capacity) Unit:
(Imp pts) Engine

BKR6EY-11

Hot

—

Cold

—

Plug gap

mm (in)

1.0 - 1.1 (0.039 - 0.043)

SR20DE M/T

6.6 (11 - 5/8)

CVT

6.8 (12)

With reservoir tank Reservoir tank

NGK

Ignition lead Ignition lead

0.8 (1 - 3/8)

Unit: kΩ/m Resistance [at 25°C (77°F)]

No. 1 cylinder

Approx 3.8

No. 2 cylinder

Approx 3.5

No. 3 cylinder

Approx 2.7

No. 4 cylinder

Approx 2.4

For U.K. (Made by Bougicord) 4.48 - 6.72 kΩ (1.365 - 2.048 kΩ/ft) [at 25°C (77°F)]

MA-57

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance INSPECTION AND ADJUSTMENT Drive belt deflection Deflection adjustment

Unit: mm (in)

Used belt

New belt

Limit

After adjustment

Alternator

17 (0.67)

10.5 - 12.5 (0.413 - 0.492)

8.5 - 10.5 (0.335 - 0.413)

Air conditioner compressor

17 (0.67)

11.5 - 13.5 (0.453 - 0.531)

9.5 - 11.5 (0.374 - 0.453)

Power steering oil pump

8 (0.31)

5-7 (0.20 - 0.28)

4-6 (0.16 - 0.24)

Applied pushing force

98 N (10 kg, 22 lb)

Coolant capacity (Refill capacity)

Injection nozzle Unit: kPa (bar, kg/cm2, psi)

Unit:
(Imp pts) With reservoir tank

6.4 (11 - 1/4)

Reservoir tank

0.8 (1 - 3/8)

Injection pressure

Engine oil capacity (Refill capacity) Unit:
(Imp pts) With oil filter

5.0 (8 - 3/4)

Without oil filter

4.5 (7 - 7/8)

MA-58

12,749 (127.5, 130, 1,849)

SERVICE DATA AND SPECIFICATIONS (SDS) Chassis and Body Maintenance Wheel balance Wheel balance (Maximum allowable unbalance at rim flange) g (oz) Tire balance weight

g (oz)

10 (0.35) 5 - 60 (0.18 - 2.12) Spacing 5 (0.18)

MA-59

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

MA-60

ENGINE MECHANICAL SECTION

EM

CONTENTS PRECAUTIONS ...............................................................5 Parts Requiring Angular Tightening.............................5 Liquid Gasket Application Procedure ..........................5 PREPARATION................................................................6 Special Service Tools ..................................................6 Commercial Service Tools .........................................10 QG NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................11 NVH Troubleshooting - Engine Noise .......................11 OUTER COMPONENT PARTS .....................................13 Removal and Installation ...........................................13 MEASUREMENT OF COMPRESSION PRESSURE ....16 OIL PAN .........................................................................17 Components...............................................................17 Removal.....................................................................17 Installation..................................................................18 TIMING CHAIN ..............................................................19 Components...............................................................19 Removal.....................................................................20 Inspection...................................................................24 Installation..................................................................24 OIL SEAL.......................................................................29 Replacement..............................................................29 VALVE OIL SEAL .....................................................29 FRONT OIL SEAL ....................................................29 REAR OIL SEAL ......................................................30 CYLINDER HEAD..........................................................31 Components...............................................................31 Removal.....................................................................32 Disassembly...............................................................34 Inspection...................................................................34 CYLINDER HEAD DISTORTION ...............................34 CAMSHAFT VISUAL CHECK ....................................34 CAMSHAFT RUNOUT ..............................................35

CAMSHAFT CAM HEIGHT .......................................35 CAMSHAFT JOURNAL CLEARANCE ........................35 CAMSHAFT END PLAY ............................................36 CAMSHAFT SPROCKET RUNOUT ...........................36 VALVE GUIDE CLEARANCE ....................................36 VALVE GUIDE REPLACEMENT ................................37 VALVE SEATS .........................................................38 REPLACING VALVE SEAT FOR SERVICE PARTS .....38 VALVE DIMENSIONS ...............................................39 VALVE SPRING .......................................................39 VALVE LIFTER AND VALVE SHIM.............................40

Valve Clearance.........................................................40 CHECKING .............................................................40 ADJUSTING ............................................................41 Assembly ...................................................................43 Installation..................................................................43 ENGINE REMOVAL.......................................................48 Removal and Installation ...........................................48 REMOVAL ...............................................................49 INSTALLATION ........................................................51 CYLINDER BLOCK .......................................................52 Components...............................................................52 Removal and Installation ...........................................53 Disassembly...............................................................53 PISTON AND CRANKSHAFT ....................................53 Inspection...................................................................54 PISTON AND PISTON PIN CLEARANCE...................54 PISTON RING SIDE CLEARANCE ............................54 PISTON RING END GAP ..........................................54 CONNECTING ROD BEND AND TORSION ...............55 CYLINDER BLOCK DISTORTION AND WEAR ...........55 PISTON-TO-BORE CLEARANCE ..............................56 CRANKSHAFT.........................................................57 BEARING CLEARANCE ...........................................57 CONNECTING ROD BUSHING CLEARANCE (Small end) ..............................................................59 REPLACEMENT OF CONNECTING ROD BUSHING (Small end) ..............................................60 FLYWHEEL/DRIVE PLATE RUNOUT .........................60

EM

CONTENTS Assembly ...................................................................60 PISTON ..................................................................60 CRANKSHAFT.........................................................61

Inspection.................................................................110 PISTON AND PISTON PIN CLEARANCE.................110 PISTON RING SIDE CLEARANCE .......................... 111 PISTON RING END GAP ........................................ 111 CONNECTING ROD BEND AND TORSION ............. 111 CYLINDER BLOCK DISTORTION AND WEAR .........112 PISTON-TO-BORE CLEARANCE ............................112 CRANKSHAFT.......................................................113 BEARING CLEARANCE .........................................114

SR20DE NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................................64 NVH Troubleshooting - Engine Noise .......................65 OUTER COMPONENT PARTS .....................................66 COMPRESSION PRESSURE........................................69 Measurement of Compression Pressure...................69 OIL PAN .........................................................................70 Removal.....................................................................70 Installation..................................................................73 TIMING CHAIN ..............................................................75 Components...............................................................75 Removal.....................................................................76 Inspection...................................................................79 Installation..................................................................79 OIL SEAL REPLACEMENT ..........................................84 VALVE OIL SEAL .....................................................84 FRONT OIL SEAL ....................................................84 REAR OIL SEAL ......................................................85 CYLINDER HEAD..........................................................86 Components...............................................................86 Removal.....................................................................87 Disassembly...............................................................89 Inspection...................................................................91 CYLINDER HEAD DISTORTION ...............................91 CAMSHAFT VISUAL CHECK ....................................91 CAMSHAFT RUNOUT ..............................................92 CAMSHAFT CAM HEIGHT .......................................92 CAMSHAFT JOURNAL CLEARANCE ........................92 CAMSHAFT END PLAY ............................................93 CAMSHAFT SPROCKET RUNOUT ...........................93 VALVE GUIDE CLEARANCE ....................................93 VALVE GUIDE REPLACEMENT ................................94 VALVE SEATS .........................................................95 REPLACING VALVE SEAT FOR SERVICE PARTS .....95 VALVE DIMENSIONS ...............................................95 VALVE SPRING .......................................................96 HYDRAULIC LASH ADJUSTER ................................96 ROCKER ARM, SHIM AND ROCKER ARM GUIDE .....97 Assembly ...................................................................97 Installation..................................................................99 ENGINE REMOVAL.....................................................106 Components.............................................................106 Removal...................................................................107 Installation................................................................108 CYLINDER BLOCK .....................................................109 Components.............................................................109 Disassembly.............................................................110 PISTON AND CRANKSHAFT ..................................110

(Cont’d)

CONNECTING ROD BUSHING CLEARANCE (Small end) ............................................................116 REPLACEMENT OF CONNECTING ROD BUSHING (Small end) ............................................117 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (CVT) ....................................117 FLYWHEEL/DRIVE PLATE RUNOUT .......................117

Assembly .................................................................117 PISTON ................................................................117 CRANKSHAFT.......................................................118 CD20T NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................121 NVH Troubleshooting Chart - Engine Noise ...........122 OUTER COMPONENT PARTS ...................................123 COMPRESSION PRESSURE......................................126 OIL PAN .......................................................................129 Removal...................................................................129 Installation................................................................129 TIMING BELT...............................................................131 Camshaft Timing Belt ..............................................131 REMOVAL .............................................................131 Inspection.................................................................133 Installation................................................................134 Injection Pump Timing Belt......................................135 REMOVAL .............................................................135 INSTALLATION ......................................................136 OIL SEAL REPLACEMENT ........................................138 VALVE OIL SEAL ...................................................138 CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING DIRECTION AND MANNER ................138 CAMSHAFT OIL SEALS .........................................138 CRANKSHAFT FRONT OIL SEAL ...........................139 CRANKSHAFT REAR OIL SEAL .............................139

CYLINDER HEAD........................................................140 Components.............................................................140 Removal...................................................................141 Disassembly.............................................................141 Inspection.................................................................142 CYLINDER HEAD DISTORTION .............................142 VALVE GUIDE CLEARANCE ..................................142 VALVE GUIDE REPLACEMENT ..............................142 VALVE SEATS .......................................................143 VALVE SEAT REPLACEMENT ................................143

EM-2

CONTENTS VALVE DIMENSIONS .............................................144 VALVE SPRING SQUARENESS ..............................145 VALVE SPRING PRESSURE LOAD ........................145 VALVE LIFTER ......................................................145 COMBUSTION CHAMBER REPLACEMENT ............146 CAMSHAFT VISUAL CHECK ..................................147 CAMSHAFT END PLAY ..........................................147 CAMSHAFT RUNOUT ............................................147 CAMSHAFT CAM HEIGHT .....................................147 CAMSHAFT JOURNAL CLEARANCE ......................147

Valve clearance .......................................................148 Checking ..................................................................148 Adjusting ..................................................................149 Assembly .................................................................151 Installation................................................................151 TURBOCHARGER.......................................................156 Removal...................................................................156 Disassembly.............................................................157 Inspection.................................................................158 OIL AND WATER TUBES........................................158 ROTOR SHAFT .....................................................158 TURBINE WHEEL ..................................................159 COMPRESSOR WHEEL .........................................159 WASTEGATE VALVE..............................................160 WASTEGATE VALVE ACTUATOR ...........................160 Assembly .................................................................160 Installation................................................................160 ENGINE REMOVAL.....................................................162 CYLINDER BLOCK .....................................................166 Components.............................................................166 Preparation ..............................................................167 Disassembly.............................................................167 PISTON AND CRANKSHAFT ..................................167 Inspection.................................................................168 PISTON AND PISTON PIN CLEARANCE.................168 PISTON RING SIDE CLEARANCE ..........................168 PISTON RING END GAP ........................................169 MAIN BEARING CLEARANCE ................................169 CONNECTING ROD BEARING CLEARANCE (Big end) ......................................................................170 CONNECTING ROD AND PISTON PIN CLEARANCE (Small end) .......................................171 CONNECTING ROD BEND AND TORSION .............172 CRANKSHAFT.......................................................172 CYLINDER BLOCK DISTORTION ...........................173 CYLINDER BORE ..................................................173 PISTON-TO-BORE CLEARANCE ............................174

Assembly .................................................................175 PISTON ................................................................175 CRANKSHAFT.......................................................175 PISTON WITH CONNECTING ROD ........................176 FLYWHEEL RUNOUT.............................................177

(Cont’d) QG

SERVICE DATA AND SPECIFICATIONS (SDS) ........178 General Specifications.............................................178 Compression Pressure ............................................178 Cylinder Head ..........................................................178 Valve ........................................................................179 VALVE...................................................................179 VALVE SPRING .....................................................179 VALVE LIFTER ......................................................179 VALVE CLEARANCE ..............................................179 VALVE GUIDE .......................................................180 AVAILABLE SHIMS ................................................180 VALVE SEAT .........................................................182 VALVE SEAT RESURFACE LIMIT ...........................183 Camshaft and Camshaft Bearing ............................183 Cylinder Block..........................................................184 Piston, Piston Ring and Piston Pin .........................185 PISTON ................................................................185 PISTON RING .......................................................185 PISTON PIN ..........................................................185 Connecting Rod .......................................................186 Crankshaft................................................................186 Main Bearing............................................................186 STANDARD ...........................................................186 UNDERSIZE ..........................................................186 Connecting Rod Bearing .........................................187 STANDARD SIZE ...................................................187 UNDERSIZE ..........................................................187 Bearing Clearance ...................................................187 Miscellaneous Components.....................................187 SR20DE SERVICE DATA AND SPECIFICATIONS (SDS) ........188 General Specifications.............................................188 Inspection and Adjustment ......................................188 COMPRESSION PRESSURE .................................188 CYLINDER HEAD ..................................................188 VALVE...................................................................189 CAMSHAFT AND CAMSHAFT BEARING .................192 CYLINDER BLOCK ................................................192 PISTON, PISTON RING AND PISTON PIN ..............193 CONNECTING ROD...............................................193 CRANKSHAFT.......................................................194 AVAILABLE MAIN BEARING ...................................194 AVAILABLE CONNECTING ROD BEARING .............195 MISCELLANEOUS COMPONENTS .........................195 CD20T SERVICE DATA AND SPECIFICATIONS (SDS) ........196 General Specifications.............................................196 Inspection and Adjustment ......................................196 COMPRESSION PRESSURE .................................196 CYLINDER HEAD ..................................................196

EM-3

CONTENTS CAMSHAFT AND CAMSHAFT BEARING .................196 VALVE...................................................................197 VALVE LIFTER ......................................................198 AVAILABLE SHIMS ................................................198 VALVE CLEARANCE..............................................198 CYLINDER BLOCK ................................................199

EM-4

(Cont’d) PISTON, PISTON RING AND PISTON PIN ..............199 CONNECTING ROD...............................................200 CRANKSHAFT.......................................................200 AVAILABLE MAIN BEARINGS .................................200 TURBOCHARGER .................................................201 MISCELLANEOUS COMPONENTS .........................201

PRECAUTIONS Parts Requiring Angular Tightening

Parts Requiring Angular Tightening I I

I

I I I

Some important engine parts are tightened using an angulartightening method rather than a torque setting method. If these parts are tightened using a torque setting method, dispersal of the tightening force (axial bolt force) will be two or three times that of the dispersal produced by using the correct angular-tightening method. Although the torque setting values (described in this manual) are equivalent to those used when bolts and nuts are tightened with an angular-tightening method, they should be used for reference only. To assure the satisfactory maintenance of the engine, bolts and nuts must be tightened using an angular-tightening method. Before tightening the bolts and nuts, ensure that the thread and seating surfaces are clean and then coated with engine oil. The bolts and nuts which require the angular-tightening method are as follows: (1) Cylinder head bolts ..... SR, CD, QG (2) Main bearing cap bolts ..... SR (3) Connecting rod cap nuts ..... SR, QG

Liquid Gasket Application Procedure a. Inner side

b. Groove

Bolt hole

SEM164F

c.

d.

Groove

Before applying liquid gasket, use a scraper to remove all traces of old liquid gasket from mating surface and groove, and then completely clean any oil stains from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) I Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for QG and CD engine (for oil pan). I Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket to inner surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) Wait at least 30 minutes before refilling with engine oil and engine coolant.

Inner side AEM080

EM-5

PREPARATION Special Service Tools

Special Service Tools Tool number Tool name

Engine application

Description

ST0501S000 Engine stand assembly 1 ST05011000 p Engine stand 2 ST05012000 p Base

SR

CD

QG

X

X

X

X

—

X

X

—

—

—

—

X

—

X

—

X

—

X

When overhauling engine

NT042

KV10106500 Engine stand shaft

When overhauling engine

NT028

KV10115300 Engine sub-attachment

When overhauling engine

NT008

Engine attachment assembly 1 KV10106500 p Engine attachment 2 KV10113300 p Sub-attachment

When overhauling engine

NT029 1 KV10108101 p

2 p

When overhauling engine

Engine attachment KV10102500 Engine stand shaft

NT366

ST10120000 Cylinder head bolt wrench

Loosening and tightening cylinder head bolt

a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39)

Unit: mm (in)

NT583

EM-6

PREPARATION Special Service Tools (Cont’d)

Tool number Tool name

Engine application

Description

KV10116200 Valve spring compressor 1 KV10115900 p Attachment

SR

CD

QG

X

—

X

—

X

—

Disassembling and assembling valve mechanism

NT022

KV101092S0 Valve spring compressor 1 KV10109210 p Compressor 2 KV10109220 p Adapter

Disassembling and assembling valve mechanism

NT021

KV10115600 Valve oil seal drift

Installing valve oil seal

Side A

Side B

Side A a: 20 (0.79) b: 13 (0.51) c: 10.3 (0.406) d: 8 (0.31) e: 10.7 (0.421) f: 5 (0.20)

Side B 20 (0.79) 14.2 (0.559) 11 (0.43) 8 (0.31) 10.7 (0.421) 5 (0.20)

X (Side B)

X — (Side A)

Unit: mm (in)

NT603

KV10107902 Valve oil seal puller 1 KV10116100 p Valve oil seal puller adapter

Removing valve oil seal

X

X

X

—

—

X

—

X

X

X

X

X

NT605

KV10115700 Dial gauge stand

Adjusting shims

NT012

KV101151S0 Lifter stopper set 1 KV10115110 p Camshaft pliers 2 KV10115120 p Lifter stopper

Changing shims

NT041

EM03470000 Piston ring compressor

Installing piston assembly into cylinder bore

NT044

EM-7

PREPARATION Special Service Tools (Cont’d)

Tool number Tool name KV10107400 Piston pin press stand 1 KV10107310 p Center shaft 2 ST13040020 p Stand 3 ST13040030 p Spring 4 KV10107320 p Cap 5 ST13040050 p Drift

Engine application

Description

SR

CD

QG

X

—

X

—

X

—

—

X

—

—

X

—

—

X

—

X

X

X

Disassembling and assembling piston pin

NT013

KV10109300* Pulley holder

Removing and installing camshaft sprocket

a: 68 mm (2.68 in) b: 8 mm (0.31 in) dia.

NT628

ED19600000* Compression gauge set

Measuring compression pressure

NT626

KV11100300 Nozzle holder socket No. 2-4 injection nozzle holder socket

Loosening and tightening injector nozzle

NT563

KV119E0030 No. 1 injection nozzle holder socket

Loosening and tightening injector nozzle

NT648

KV10111100 Seal cutter

Removing oil pan

NT046

*: Special tool or commercial equivalent

EM-8

PREPARATION Special Service Tools (Cont’d)

Tool number Tool name

Engine application

Description

WS39930000 Tube presser

SR

CD

QG

X

X

X

X

X

X

X

X

—

—

X

—

—

X

X

Pressing the tube of liquid gasket

NT052

KV10112100 Angle wrench

Tightening bolts for bearing cap, cylinder head, etc.

NT014

ST16610001* Pilot bushing puller

Removing pilot bushing

NT045

KV11102900* Pulley puller

Removing injection pump pulley

NT647

KV101056S0* Ring gear stopper 1 KV10105630 p Adapter 2 KV10105620 p Adapter 3 KV10105610 p Plate assembly

Preventing crankshaft from rotating

a: 3 (0.12) b: 6.4 (0.252) c: 2.8 (0.110) d: 6.6 (0.260) e: 107 (4.21) f: 14 (0.55) g: 20 (0.79) h: 14 (0.55) dia.

Unit: mm (in)

NT617

*: Special tool or commercial equivalent

EM-9

PREPARATION Commercial Service Tools

Commercial Service Tools Tool name

Engine application

Description

Spark plug wrench

SR

CD

QG

X

—

X

X

X

X

X

X

X

X

—

X

X

—

X

X

—

X

X

—

X

Removing and installing spark plug

16 mm (0.63 in) NT047

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring expander

Removing and installing piston ring

NT030

Valve guide drift

Removing and installing valve guide SR Intake & Exhaust a = 9.5 mm (0.374 in) dia. b = 5.0 mm (0.197 in) dia. QG Intake & Exhaust a = 9.5 mm (0.374 in) dia. b = 5.5 mm (0.217 in) dia.

NT015

Reaming valve guide p 1 or hole for oversize valve guide

Valve guide reamer

2 p

SR d1 = d2 = QG d1 = d2 =

Front oil seal drift

Intake & Exhaust 6.0 mm (0.236 in) dia. 10.175 mm (0.4006 in) dia. Intake & Exhaust 5.5 mm (0.217 in) dia. 9.685 mm (0.3813 in) dia.

Installing front oil seal

NT016

a = 75 mm (2.95 in) dia. b = 45 mm (1.77 in) dia.

NT049

Rear oil seal drift

Installing rear oil seal

a = 110 mm (4.33 in) dia. b = 80 mm (3.15 in) dia.

NT049

EM-10

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

QG

NVH Troubleshooting — Engine Noise

NVH Troubleshooting — Engine Noise

NCEM0005S01

Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise

Type of noise

Top of Engine Rocker Cover Cylinder Head Crankshaft Pulley Cylinder block (Side of Engine) Oil pan

Source of noise

Reference page

Before After warm- warmup up

When starting

When idling

When While racing driving

Ticking or click

C

A

—

A

B

—

Tappet noise

Valve clearance

EM-40

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-35

Slap or knock

—

A

—

B

B

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-54, 59

Slap or rap

A

—

—

B

B

A

Piston slap noise

Piston-to-bore clearance EM-54, 55, Piston ring side clearance 56 Piston ring end gap Connecting rod bend and torsion

Knock

A

B

C

B

B

B

Connecting rod-bearing noise

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

EM-58, 59

Knock

A

B

—

A

B

C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-57

Front of Tapping or A Engine Tim- ticking ing Chain Cover

A

—

B

B

B

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-24

Front of Engine

Squeak or A fizzing

B

—

B

—

C

Other drive belts (sticking or slipping)

Drive belts deflection

Creaking

A

B

A

B

A

B

Other drive belts (slipping)

Idler pulley bearing operation

MA Section (“Checking Drive Belts”, “Engine Maintenance”)

Squall or creak

A

B

—

B

A

B

Water pump Water pump operation noise

A: Closely related

B: Related

C: Sometimes related

—: Not related

EM-11

Check item

LC Section (“Water Pump Inspection”, “Engine Cooling System”)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

QG

NVH Troubleshooting — Engine Noise (Cont’d)

Camshaft bearing noise

Tappet noise

Timing chain and chain tensioner noise

VALVE MECHANISM

Valve TIMING CHAIN

Water pump noise

Piston pin noise

ROTATION MECHANISM

DRIVE BELT

Connecting rod bearing noise Piston slap noise

Main bearing noise SEM937F

EM-12

QG

OUTER COMPONENT PARTS

Removal and Installation

Removal and Installation

NCEM0006

YEM026

1. 2. 3. 4.

Oil pressure switch EGR valve* EGR guide tube* Air relief plug

5. 6. 7. 8.

Intake manifold Intake manifold upper support Intake manifold rear supports Oil filter

*: If so equipped

EM-13

9. Thermostat 10. Water pump 11. Water pump pulley

QG

OUTER COMPONENT PARTS Removal and Installation (Cont’d)

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) .

1st 12 - 14 (1.2 - 1.4, 9 - 10) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

2nd 17 - 24 (1.7 - 2.4, 12 - 17)

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 2.0 - 2.5 (0.20 - 0.26, 17.4 - 22.6)

Gasket Clip .

2.9 - 3.8 (0.30 - 0.39, 26.0 - 33.9)

O-ring O-ring

Gasket

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

Gasket

3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6) 3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6)

17 - 24 (1.7 - 2.4, 12 - 17)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

17 - 24 (1.7 - 2.4, 12 - 17)

: Do not re-use. Intake manifold bolts and nuts tightening order

Throttle body bolts tightening procedure 1) Tighten all bolts to 9 to 11 N·m (0.9 to 1.1 kg-m, 6.5 to 8.0 ft-lb) 2) Tighten all bolts to 18 to 22 N·m (1.8 to 2.2 kg-m, 13 to 16 ft-lb)

Engine front Tighten in numerical order.

Tighten in numerical order. SEM865F

1. 2. 3.

Throttle position sensor IACV-AAC valve Throttle body

4. 5. 6.

Injector Injector tube Pressure regulator

EM-14

7. 8.

Intake manifold Canister purge control valve

QG

OUTER COMPONENT PARTS

Removal and Installation (Cont’d)

5.10 - 6.37 (0.52 - 0.66, 45.1 - 57.3)

13 p

20 - 26 (2.0 - 2.7, 14 - 20)

20 - 29 (2.0 - 3.0, 14 - 22)

Washer 20 - 29 (2.0 - 3.0, 14 - 22) 30 - 40 (3.1 - 4.0, 23 - 29) 40 - 60 (4.1 - 6.1, 30 - 44)

58.8 - 78.4 (6.0 - 8.0, 43 - 58)

29 - 34 (3.0 - 3.5, 22 - 25) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 34.3 - 44.1 (3.50 - 4.50, 25.3 - 32.5)

Washer

132 - 152 (13.5 - 15.5, 98 - 112) ★

26 - 29 (2.7 - 3.0, 20 - 22)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

29 - 34 (3.0 - 3.5, 22 - 25) Exhaust manifold nuts tightening order

6.3 - 8.3 (0.64 - 0.83, 55.6 - 72.0)

33 - 46 (3.4 - 4.7, 25 - 34) 16 - 21 (1.6 - 2.1, 12 - 15)

: N·m (kg-m, in-lb)

33 - 46 (3.4 - 4.7, 25 - 34)

: N·m (kg-m, ft-lb)

Engine front

6.3 - 8.3 (0.64 - 0.83, 55.6 - 72.0)

: Use Genuine Liquid Gasket or equivalent.

16 - 21 (1.6 - 2.1, 12 - 15)

: Do not re-use.

Tighten in numerical order.

: Lubricate with new engine oil. SEM866F

1. 2. 3. 4. 5.

Crankshaft pulley Engine coolant temperature Gasket Exhaust manifold Exhaust manifold cover

6. 7. 8. 9.

Thermal transmitter Water drain plug Heated oxygen sensor Three way catalyst

EM-15

10. 11. 12. 13.

Converter cap Converter cover Ignition coil Spark plug

MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3. 4. 5. I

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC section. Remove ignition coils. Remove spark plugs. Clean area around plug with compressed air before removing the spark plug.

6. 7.

SEM973E

20 mm (0.79 in) dia. Use compression tester whose end (rubber portion) is less than 20 mm (0.79 in) dia. Otherwise, it may be caught by cylinder head during removal.

AEM308

QG

Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. I Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (bar, kg/cm2, psi)/rpm Standard 1,324 (13.24, 13.5, 192)/350 Minimum 1,128 (11.28, 11.5, 164)/350 Maximum allowable difference between cylinders 98 (0.98, 1.0, 14)/300 10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and retest compression. I If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. I If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to SDS, EM-178. If valve or valve seat is damaged excessively, replace them. I If compression in any two adjacent cylinders is low and if adding oil does not improve compression, there is leakage past the gasket surface. If so, replace cylinder head gasket. 11. Reinstall spark plugs, ignition coils and fuel pump fuse. 12. Perform “Self-diagnosis Procedure” referring to EC section. Erase DTC if any DTC appears.

EM-16

QG

OIL PAN

Components

Components

NCEM0008

Gasket Oil pan Oil pan side

Oil strainer

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Washer

Drain plug 29.4 - 39.2 (3.00 - 4.00, 21.69 - 28.91) 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8) 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)

6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)

: Use Genuine Liquid Gasket or equivalent

SEM867F

Removal 1. 2. 3. Centre member

NCEM0009

5.

Remove engine RH side cover and under covers. Drain engine oil. Remove front exhaust tube. Refer to FE section (“EXHAUST SYSTEM”). Set a suitable transmission jack under transaxle and lift engine with engine slinger. Remove center member.

6.

Remove rear engine gussets.

4.

SEM067F

Drain plug Lower rear engine plate

Gusset .

SEM071FA

EM-17

OIL PAN

QG

Removal (Cont’d)

7. a. 1)

b.

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

SEM365EB

Installation 1. I

NCEM0010

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

Scraper SEM295C

2.

Cut here. 7 mm (0.28 in)

I I I

Liquid gasket

Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. Apply to groove on mating surface. Allow 7 mm (0.28 in) clearance around bolt holes.

Inner side

Groove

Bolt hole SEM015E

I

Tube presser

I

Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). Attaching should be done within 5 minutes after coating.

3. I I 4.

Install oil pan. Tighten oil pan nuts and bolts in the numerical order. Wait at least 30 minutes before refilling engine oil. Install parts in reverse order of removal.

SEM296CB

Engine front

SEM072F

EM-18

QG

TIMING CHAIN

Components

Components

NCEM0011

108 - 118 (11.0 - 12.0, 80 - 87)

7.2 - 10.8 (0.73 - 1.10, 63.4 - 95.5) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

O-ring

98 - 128 (10.0 - 13.1, 72 - 95)

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 17 - 24 (1.7 - 2.4, 12 - 17)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

17 - 24 (1.7 - 2.4, 12 - 17)

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 16 - 21 (1.6 - 2.1, 12 - 15) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 132 - 152 (13.5 - 15.5, 98 - 112)

: Use Genuine Liquid Gasket or equivalent : Lubricate with new engine oil. : Do not re-use. SEM868F

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

Chain tensioner Camshaft sprocket (Intake) Camshaft sprocket (Exhaust) O-ring Slack side timing chain guide Timing chain tension guide

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

Timing chain Crankshaft sprocket Oil pump drive spacer Front cover O-ring Oil seal

EM-19

13. Crankshaft pulley 14. Cylinder head front cover 15. Camshaft position sensor (PHASE) 16. Cylinder block dowels

TIMING CHAIN

QG

Components (Cont’d)

CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley. I When removing oil pump assembly, remove camshaft position sensor (PHASE), then remove timing chain from engine. I Be careful not to damage sensor edges.

Removal

Drain plug

1. 2.

SEM869F

3. I I 4. 5. 6. 7. 8.

NCEM0012

Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Release fuel pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). Remove the following belts. Power steering pump drive belt Alternator drive belt Remove power steering pulley and pump with bracket. Remove front right-side wheel. Remove front right-side splash cover. Remove front undercovers. Remove front exhaust tube.

9. Remove vacuum hoses, fuel hoses, and so on. 10. Remove ignition coils. 11. Remove cylinder head front mounting bracket.

Ignition coil Engine front SEM870F

12. Remove rocker cover bolts in numerical order as shown in the figure. 13. Remove spark plugs.

Remove in numerical order. SEM871F

EM-20

QG

TIMING CHAIN

Removal (Cont’d)

14. Set No. 1 piston at TDC on its compression stroke.

SEM872F

I

Mating mark

(INT) RH camshaft sprocket

Mating mark

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.

(EXH) LH camshaft sprocket SEM873F

15. Remove camshaft position sensor (PHASE). I Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). I Be careful not to damage sensor. 16. Remove cylinder head front cover.

Cylinder head front cover

O-ring

Camshaft position sensor (PHASE)

SEM874F

17. Remove timing chain guide from camshaft bracket. 18. Attach a suitable stopper pin to chain tensioner. 19. Remove chain tensioner.

Chain guide

Stopper pin Chain tensioner

SEM875F

Mating mark

20. Remove camshaft sprocket bolts. I Apply paint to timing chain and cam sprockets for alignment during installation. 21. Remove camshaft sprockets.

SEM876F

EM-21

TIMING CHAIN

QG

Removal (Cont’d)

22. Remove cylinder head bolts at engine front side.

Engine front

Loosen in numerical order.

SEM008G

23. 24. 25. 26.

Remove center member. Support engine with a suitable hoist or jack. Remove oil pan. Refer to “Removal” in “OIL PAN” (EM-17). Remove oil strainer.

Oil strainer SEM879F

27. Remove starter motor, and set ring gear stopper using mounting bolt holes.

SEM880F

28. Loosen crankshaft pulley bolt. 29. Remove crankshaft pulley with a suitable puller. Suitable puller

Crankshaft pulley SEM881F

30. Remove engine front mounting.

Engine front mounting

SEM079FA

EM-22

QG

TIMING CHAIN

Removal (Cont’d)

31. Remove engine front mounting bracket. Engine front mounting bracket

SEM882F

32. Remove water pump pulley and water pump. 33. Remove front cover bolts and front cover as shown. ★1: Located on water pump ★2: Located on power steering pump adjusting bar I Inspect for oil leakage at front oil seal. Replace seal if oil leak is present.

SEM883F

Timing chain Chain guides

O-rings

34. 35. 36. 37. 38.

Remove Remove Remove Remove Remove

timing chain. oil pump drive spacer. chain guides. crankshaft sprocket. O-rings from cylinder block and front cover.

Crankshaft sprocket Oil pump drive spacer SEM884F

O-rings

SEM897F

39. Remove cylinder block dowels by using locking pliers for easyto-install front cover. I Do not hit dowels because cylinder block may be cracked.

Locking pliers

Cylinder block dowels

SEM944F

EM-23

TIMING CHAIN

QG

Inspection

Inspection

NCEM0013

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

Crack

Wear

SEM885F

Crankshaft sprocket

Crankshaft side

Installation

NCEM0014

1. I

Install crankshaft sprocket on crankshaft. Make sure mating marks on crankshaft sprocket face front of engine.

2.

Position crankshaft so that No. 1 piston is at TDC and key way is at 12 o’clock.

3.

Install slack side timing chain guide and timing chain tension guide.

4. I

Install timing chain on crankshaft sprocket. Set timing chain by aligning its mating mark with that on the crankshaft sprocket. Make sure sprocket’s mating mark faces engine front.

Engine front Mating mark

SEM886F

Crankshaft key

No. 1 piston at TDC

SEM890F

Slack side timing chain guide Timing chain tension guide

SEM891F

Crankshaft sprocket Timing chain

I

Mating mark (different colour) SEM892F

EM-24

QG

TIMING CHAIN

Installation (Cont’d)

5.

Install O-rings to cylinder block.

6.

Before installing front cover, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.

O-rings

SEM893F

Scraper

I

SEM894F

7. I I I

Liquid gasket

Front cover

2.0 - 3.0 mm (0.079 0.118 in) dia.

Apply a continuous bead of liquid gasket to mating surface of front cover. Check alignment of mating marks on chain and crankshaft sprocket. Align oil drive spacer with oil pump. Place timing chain to the side of chain guide. This prevents the chain from making contact with water seal area of front cover.

SEM895F

8.

Install front cover. Bolt No.

Tightening torque

N⋅m (kg-m, in-lb)

“”

mm (in)

a.

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

20 (0.79)

b.

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

40 (1.57)

c.

17 - 24 (1.7 - 2.4, 148 - 208*)

70 (2.76)

d.

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

72.8 (2.866)

e.

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

12 (0.47)

SEM896F

*: 12 - 17 ft-lb

I I

O-rings

Make sure two O-rings are present. Be careful not to damage oil seal when installing front cover.

SEM897F

EM-25

TIMING CHAIN

QG

Installation (Cont’d)

9. I

Engine front

Tighten in numerical order

Install cylinder head bolts at engine front side. Tightening procedure Tightening bolts (1 - 4) to 6.3 to 8.3 N⋅m (0.64 to 0.85 kg-m, 55.8 to 73.5 in-lb).

SEM009G

10. Install oil pump drive spacer. Oil pump drive spacer

Point mark

SEM945F

11. Install cylinder block dowels. I When installing cylinder block dowels, use new ones.

Cylinder block dowels

SEM946F

Engine front mounting bracket

SEM898F

12. Install water pump and water pump pulley. Refer to LC section (“Water Pump”, “ENGINE COOLING SYSTEM”). 13. Install engine front mounting bracket. 14. Install oil strainer. 15. Install oil pan. Refer to “Installation” in “OIL PAN” EM-18. 16. Install crankshaft pulley. 17. Install center member. 18. Remove ring gear stopper. 19. Install starter motor. 20. Install camshaft sprocket. I Set timing chain by aligning mating marks with those of camshaft sprockets.

Mating mark Mating mark Camshaft sprocket (INT)

Camshaft sprocket (EXH)

SEM905F

EM-26

QG

TIMING CHAIN

Installation (Cont’d)

21. Install camshaft sprocket bolts to correct torque. I Apply new engine oil to bolt threads and seat surface.

SEM906F

22. Install chain tensioner. I Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner. I After installing chain tensioner, remove the pin. 23. Install timing chain guide.

Chain guide

Chain tensioner Stopper pin SEM907F

24. Install cylinder head front cover. I Apply liquid gasket to cylinder head front cover. I Use Genuine Liquid Gasket or equivalent.

Cylinder head front cover

2.0 - 3.0 mm (0.079 0.118 in) dia.

SEM887F

Camshaft position sensor (PHASE)

25. Install camshaft position sensor (PHASE). O-ring

SEM889F

26. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head. Liquid gasket

3 mm (0.12 in) dia.

Cylinder head Cylinder head front cover

SEM888F

EM-27

TIMING CHAIN

QG

Installation (Cont’d)

Tighten in numerical order SEM908F

27. Install rocker cover and tighten bolts in numerical order as shown in the figure. 28. Install spark plugs. 29. Install ignition coils. 30. Install engine front mounting. 31. Install front exhaust tube. 32. Install front undercover. 33. Install front right splash cover. 34. Install front right wheel. 35. Install power steering pulley and pump with bracket. To check power steering fluid, refer to MA section (“Checking Power Steering Fluid and Lines”, “CHASSIS AND BODY MAINTENANCE”). 36. Drive belts. For adjusting drive belt deflection, refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”). 37. Reinstall parts in reverse order of removal.

EM-28

OIL SEAL

QG Replacement

Replacement VALVE OIL SEAL

NCEM0015 NCEM0015S01

1. Remove rocker cover. 2. Remove camshaft. 3. Remove valve spring. Refer to EM-34. 4. Remove valve oil seal with Tool. Piston concerned should be set at TDC to prevent valve from falling.

KV10107902

SEM909F

5. 13.5± 0.3 mm (0.531± 0.012 in)

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

KV10115600 SEM910F

FRONT OIL SEAL Front oil seal

NCEM0015S02

1. I I I I 2. I

Remove the following parts: Engine under cover RH engine side cover Generator and power steering drive belts Crankshaft pulley Remove front oil seal from front cover. Be careful not to scratch front cover.

3.

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

SEM911F

I Engine inside

Oil seal lip

Engine outside

Dust seal lip

SEM715A

Suitable tool

SEM912F

EM-29

OIL SEAL

QG

Replacement (Cont’d)

REAR OIL SEAL

NCEM0015S03

1. 2. I

Remove flywheel or drive plate. Remove rear oil seal. Be careful not to scratch rear oil seal retainer.

3.

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

SEM096F

I Engine inside

Oil seal lip

Engine outside

Dust seal lip

SEM715A

Suitable tool SEM097F

EM-30

QG

CYLINDER HEAD

Components

Components

NCEM0016

To intake manifold

2.0 - 3.9 (0.20 - 0.40, 17.4 - 34.7) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Refer to “Installation” in “TIMING CHAIN”.

9 p

4 p

Refer to “Installation” in “TIMING CHAIN”.

24.5 - 34.3 (2.5 - 3.5, 18 - 25) O-ring

: N·m (kg-m, in-lb)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

: N·m (kg-m, ft-lb) : Use Genuine Liquid Gasket or equivalent. : Lubricate with new engine oil. : Do not re-use. SEM913F

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

Oil filler cap Rocker cover Rocker cover gasket VTC solenoid Camshaft bracket Intake camshaft Exhaust camshaft

8. 9. 10. 11. 12. 13. 14.

Timing chain guide Cylinder head bolt Shim Valve lifter Valve cotter Valve spring retainer Valve spring

EM-31

15. 16. 17. 18. 19. 20. 21.

Valve spring seat Valve oil seal Valve guide Cylinder head Cylinder head gasket Valve seat Valve

CYLINDER HEAD

QG

Components (Cont’d)

CAUTION: I When installing camshaft and oil seal, lubricate contacting surfaces with new engine oil. I When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil. I Attach tags to valve lifters so as not to mix them up.

Removal

Drain plug

1. 2.

3. 4. 5.

NCEM0017

Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Release fuel pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). Remove air duct to intake manifold collector. Remove front undercovers. Remove front exhaust tube.

SEM869F

6. 7.

Remove vacuum hoses, fuel hoses, water hoses, wires, harness, connectors and so on. Remove ignition coils.

Ignition coil Engine front SEM870F

8.

Remove rocker cover bolts in numerical order as shown in the figure. 9. Remove spark plugs. 10. Remove intake manifold rear supports.

Remove in numerical order. SEM871F

11. Set No. 1 piston at TDC on its compression stroke.

SEM872F

EM-32

QG

CYLINDER HEAD

Removal (Cont’d)

I

Mating mark

(INT) RH camshaft sprocket

Mating mark

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.

(EXH) LH camshaft sprocket SEM873F

12. Remove camshaft position sensor (PHASE). I Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). I Be careful not to damage sensor. 13. Remove cylinder head front cover.

Cylinder head front cover

O-ring

Camshaft position sensor (PHASE)

SEM874F

14. Remove timing chain guide from camshaft bracket. 15. Attach a suitable stopper pin to chain tensioner. 16. Remove chain tensioner.

Chain guide

Stopper pin Chain tensioner

SEM875F

17. Remove camshaft sprocket bolts. I Apply paint to timing chain and cam sprockets for alignment during installation. 18. Remove camshaft sprockets.

Mating mark

SEM876F

19. Remove camshaft brackets and camshafts. I Apply I.D. marks to brackets to ensure correct reassembly. I Bolts should be loosened in two or three steps.

Engine front

Loosen in numerical order.

877F

EM-33

CYLINDER HEAD

QG

Removal (Cont’d)

20. Remove cylinder head bolts. 21. Remove cylinder head with manifolds. I Head warpage or cracking could result from removing in incorrect order. I Cylinder head bolts should be loosened in two or three steps.

Engine front

Loosen in numerical order.

SEM878F

Disassembly 1. 2.

KV10109220

NCEM0018

Remove valve components with Tool. Remove valve oil seal with a suitable tool.

KV10116200

SEM914F

Inspection Straightedge

CYLINDER HEAD DISTORTION I I

Feeler gauge

SEM915F

NCEM0019 NCEM0019S01

Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head mating surface. I Check along six positions shown in figure. Head surface flatness: Standard: Less than 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface it. Resurfacing limit: The limit for cylinder head resurfacing is determined by the amount of cylinder block resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, replace cylinder head. Nominal cylinder head height: 117.8 - 118.0 mm (4.638 - 4.646 in)

CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.

EM-34

NCEM0019S02

QG

CYLINDER HEAD

Inspection (Cont’d)

CAMSHAFT RUNOUT 1.

2.

NCEM0019S03

Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.

SEM154D

CAMSHAFT CAM HEIGHT 1.

Micrometer

SEM916F

2.

CAMSHAFT JOURNAL CLEARANCE

Inside micrometer

1. 2.

NCEM0019S04

Measure camshaft cam height. Standard cam height: Intake QG16DE 40.220 - 40.410 mm (1.5835 - 1.5909 in) QG18DE 40.610 - 40.800 mm (1.5988 - 1.6063 in) Exhaust 40.056 - 40.245 mm (1.5770 - 1.5844 in) Cam wear limit: 0.20 mm (0.0079 in) If wear is beyond the limit, replace camshaft.

NCEM0019S05

Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: No. 1 bearing 28.000 - 28.021 mm (1.1024 - 1.1032 in) No. 2 to No. 5 bearings 24.000 - 24.021 mm (0.9449 - 0.9457 in)

SEM917F

3.

4.

SEM156D

Measure outer diameter of camshaft journal. Standard outer diameter: No. 1 journal 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2 to No. 5 journals 23.935 - 23.955 mm (0.9423 - 0.9431 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard

EM-35

CYLINDER HEAD

QG

Inspection (Cont’d)

0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit 0.15 mm (0.0059 in)

CAMSHAFT END PLAY

Dial guage

1. 2.

SEM918F

3. I

CAMSHAFT SPROCKET RUNOUT 1. 2.

3.

NCEM0019S06

Install camshaft in cylinder head. Refer to EM-24. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit 0.20 mm (0.0079 in) If limit is exceeded, replace camshaft and remeasure end play. If limit is still exceeded after replacing camshaft, replace cylinder head.

NCEM0019S07

Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.

SEM919F

VALVE GUIDE CLEARANCE 1.

Approx. 25 mm (0.98 in)

NCEM0019S08

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

SEM345D

EM-36

QG

CYLINDER HEAD

Inspection (Cont’d)

Micrometer

2. a. b.

c.

If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Calculate valve to valve guide clearance. Valve to valve guide clearance = Valve guide inner diameter − Valve stem diameter. Check that clearance is within specification. Unit: mm (in)

SEM938C

Standard

Limit

Intake

0.020 - 0.050 (0.0008 - 0.0020)

0.1 (0.004)

Exhaust

0.040 - 0.070 (0.0016 - 0.0028)

0.1 (0.004)

I I

Oil

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

VALVE GUIDE REPLACEMENT

NCEM0019S09

1.

To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).

2.

Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

SEM008A

SEM931C

EM-37

CYLINDER HEAD

QG

Inspection (Cont’d)

3.

Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake & Exhaust 9.685 - 9.696 mm (0.3813 - 0.3817 in)

4.

Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide into cylinder head. Projection “L”: 11.5 - 11.7 mm (0.453 - 0.461 in)

5.

Ream valve guide. Finished size: Intake & Exhaust 5.500 - 5.515 mm (0.2165 - 0.2171 in)

Suitable reamer

SEM932C

MEM096A

Suitable reamer

SEM932C

VALVE SEATS

NCEM0019S10

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

SEM934C

REPLACING VALVE SEAT FOR SERVICE PARTS .

1. Recess diameter

SEM795A

NCEM0019S11

Bore out old seat until it collapses. Set machine depth stop so that boring cannot contact the bottom face of seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Refer to SDS, EM-182. Use the valve guide center for reaming to ensure valve seat will have the correct fit.

EM-38

QG

CYLINDER HEAD

Inspection (Cont’d) Oil

3. 4.

Heat cylinder head to 110 to 130°C (230 to 266°F). Press fit valve seat until it seats on the bottom.

5.

Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS, EM-179. After cutting, lap valve seat with abrasive compound. Check valve seating condition. Seat face angle “α”: 45°15′ - 45°45′ Contacting width “W”: Intake 1.06 - 1.34 mm (0.0417 - 0.0528 in) Exhaust 1.20 - 1.68 mm (0.0472 - 0.0661 in) Use a depth gauge to measure the distance “L” between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to correct it. If the distance is longer, replace the valve seat. Valve seat resurface limit: Intake 35.95 - 36.55 mm (1.4154 - 1.4390 in) Exhaust 35.92 - 36.52 mm (1.4142 - 1.4378 in)

SEM008A

6. 7.

SEM892B

8.

AEM343

VALVE DIMENSIONS

T (Margin thickness)

NCEM0019S12

Check dimensions of each valve. Refer to SDS, EM-182 for dimensions. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

SEM188A

S (Out-of-square)

VALVE SPRING Squareness 1.

2.

Measure dimension “S”. Out-of-square “S”: Less than 1.75 mm (0.0689 in) If it exceeds the limit, replace spring.

SEM288A

EM-39

NCEM0019S13 NCEM0019S1301

QG

CYLINDER HEAD Inspection (Cont’d)

Pressure

EM113

NCEM0019S1302

Check valve spring pressure at specified spring height. Pressure: Standard 370.0 N (37.73 kg, 83.19 lb) at 23.64 mm (0.9307 in) Limit More than 347.8 N (35.46 kg, 78.19 lb) at 23.64 mm (0.9307 in) If it exceeds the limit, replace spring.

VALVE LIFTER AND VALVE SHIM

NCEM0019S16

1.

Check contact and sliding surfaces for wear or scratches.

2.

Check diameter of valve lifter and valve lifter guide bore. Valve lifter outside diameter: 29.960 - 29.975 mm (1.1795 - 1.1801 in)

SEM160D

SEM161D

Lifter guide inside diameter: 30.000 - 30.021 mm (1.1811 - 1.1819 in) Clearance between valve lifter and valve lifter guide: 0.025 - 0.065 mm (0.0010 - 0.0024 in) If it exceeds the limit, replace valve lifter or cylinder head which exceeds the standard diameter tolerance.

SEM920F

Valve Clearance CHECKING

Pointer

NCEM0041 NCEM0041S01

Check valve clearance while engine is warm and not running. 1. Remove rocker cover. 2. Remove all spark plugs. 3. Set No. 1 cylinder at TDC on its compression stroke. I Align pointer with TDC mark on crankshaft pulley. I Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight.

Timing mark

Crankshaft pulley SEM921F

EM-40

QG

CYLINDER HEAD

Valve Clearance (Cont’d)

INT

No. 1

No. 2

No. 3

I

If not, turn crankshaft one revolution (360°) and align as described above.

4.

Check only those valves shown in the figure.

I

Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance for checking (Hot): Intake 0.21 - 0.49 mm (0.008 - 0.019 in) Exhaust 0.30 - 0.58 mm (0.012 - 0.023 in)

No. 4

EXH Engine front SEM922F

I

.

SEM139D

5.

INT

No. 1

No. 2

No. 3

No. 4

6. I 7. I I

EXH

Turn crankshaft one revolution (360°) and align mark on crankshaft pulley with pointer. Check only those valves shown in the figure. Use the same procedure as mentioned in step 4. If all valve clearances are within specification, install the following parts: Rocker cover All spark plugs

Engine front SEM923F

ADJUSTING

Tool (A) KV10115110

NCEM0041S02

Adjust valve clearance while engine is cold. 1. Turn crankshaft. Position cam lobe upward on camshaft for valve that must be adjusted. 2. Place Tool (A) around camshaft as shown in figure. Before placing Tool (A), rotate notch toward center of cylinder head. (See figure.) This will simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A).

Notch

SEM941F

EM-41

CYLINDER HEAD

QG

Valve Clearance (Cont’d)

3.

Tool (A) KV10115110

Rotate Tool (A) so that valve lifter is pushed down.

SEM924F

4. Tool (B) KV10115120

Tool (A)

Place Tool (B) between camshaft and valve lifter to retain valve lifter. CAUTION: I Tool (B) must be placed as close to camshaft bracket as possible. I Be careful not to damage cam surface with Tool (B). 5. Remove Tool (A).

SEM925F

.

Magnetic finger

6. Tool (B)

SEM144D

Remove adjusting shim using a small screwdriver and a magnetic finger. 7. Determine replacement adjusting shim size using the following formula. I Use a micrometer to determine thickness of removed shim. I Calculate thickness of new adjusting shim so valve clearance comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance Intake: N = R + [M − 0.37 mm (0.0146 in)] Exhaust: N = R + [M − 0.40 mm (0.0157 in)] Shims are available in 50 sizes from 2.00 mm (0.0787 in) to 2.98 mm (0.1173 in), in steps of 0.02 mm (0.0008 in).

SEM145D

I

Shim

Select the closest size shim to the calculated thickness. Refer to chart in SDS, EM-180.

Indicate T1 = 2.800 mm (0.1102 in) AEM236

EM-42

QG

CYLINDER HEAD

Valve Clearance (Cont’d)

8. I

Tool (B)

Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down.

Suitable tool

SEM146D

9. Place Tool (A) as explained in steps 2 and 3. 10. Remove Tool (B). 11. Remove Tool (A). 12. Recheck valve clearance. Valve clearance:

Tool (B)

Tool (A)

Unit: mm (in) For adjusting

For checking

Hot

Cold* (reference data)

Hot

Intake

0.32 - 0.40 (0.013 - 0.016)

0.25 - 0.33 (0.010 - 0.013)

0.21 - 0.49 (0.008 - 0.019)

Exhaust

0.37 - 0.45 (0.015 - 0.018)

0.32 - 0.40 (0.013 - 0.016)

0.30 - 0.58 (0.012 - 0.023)

SEM147D

*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.

Assembly 1. I I I

Narrow pitch

Wide pitch

I

Narrow pitch

NCEM0020

Install valve component parts. Always use new valve oil seal. Refer to EM-29. Before installing valve oil seal, install valve spring seat. After installing valve components, tap valve stem tip with a plastic hammer to assure a proper fit. Install valve spring (narrow pitch at both ends of spring) with either end toward cylinder head.

AEM293

Installation Liquid gasket

1.

2.0 - 3.0 mm (0.079 - 0.118 in) dia.

2. I

Engine front

NCEM0021

Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block. Install cylinder head gasket. When installing cylinder head with manifolds, use new cylinder head gasket.

SEM899F

EM-43

QG

CYLINDER HEAD Installation (Cont’d)

3. I Cylinder head bolt washer

I I

Install cylinder head with manifolds. Be sure to install washers between bolts and cylinder head. Do not rotate crankshaft and camshaft separately, or valves will strike piston heads. Apply new engine oil to cylinder head bolt threads and seat surfaces.

Cylinder head side

SEM877A

I

Engine front

Tightening procedure Tighten bolts to 29 N⋅m (3 kg-m, 22 ft-lb). Tighten bolts to 59 N⋅m (6 kg-m, 43 ft-lb). Loosen bolts completely. Tighten bolts to 29 N⋅m (3 kg-m, 22 ft-lb). Turn bolts 50 to 55 degrees clockwise or if angle wrench is not available, tighten bolts to 59±4.9 N⋅m (6±0.5 kg-m, 43±3.6 ft-lb). f Tightening bolts (11 - 14) to 6.3 to 8.3 N⋅m (0.64 to 0.85 p kg-m, 55.8 to 73.5 in-lb). a p b p c p d p e p

Tighten in numerical order. SEM900F

Tightening torque N⋅m (kg-m, ft-lb)

Tightening torque N·m (kg-m, ft-lb)

a

59 (6, 43)

Bolts (1 - 10)

29 (3, 22)

b

59 (6, 43)

c

0 (0, 0)

d

e, f

29 (3, 22)

50 - 55 degrees or 59±4.9 (6±0.5, 43±3.6 ft-lb)

—

6.3 - 8.3 (0.64 0.85, 55.8 73.5 in-lb)

29 (3, 22)

Bolts (11 - 14)

—

SEM614EC

Intake

—

—

4.

Install camshaft.

I

Make sure camshafts are aligned as shown in figure.

Exhaust SEM901F

Intake Knock pin

Exhaust Knock pin

SEM902F

EM-44

CYLINDER HEAD

QG Installation (Cont’d)

No.

Front mark

Intake side

5. I

Install camshaft brackets. Make sure camshaft brackets are aligned as marked during disassembly.

I I

Apply new engine oil to bolt threads and seat surface. Tighten camshaft bracket bolts in the following steps. a Tighten bolts 9 - 12, then 1 - 8. 2.0 N⋅m (0.204 kg-m, 17.7 in-lb) b Tighten bolts 1 - 12. 5.9 N⋅m (0.60 kg-m, 52.2 in-lb) c Tighten bolts 1 - 12. 9.8 - 11.8 N⋅m (1.00 - 1.20 kg-m, 86.7 - 104.4 in-lb) If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Refer to “Checking” and “Adjusting” in “VALVE CLEARANCE” (EM-40). Reference data valve clearance (Cold): Intake 0.25 - 0.33 mm (0.010 - 0.013 in) Exhaust 0.32 - 0.40 mm (0.013 - 0.016 in)

Intake mark

No.

Engine front Exhaust side

Front mark

Exhaust mark SEM903F

Engine front

I Tighten in numerical order.

Mating mark

Camshaft sprocket (INT)

SEM904F

6. I

Install camshaft sprocket. Set timing chain by aligning mating marks with those of camshaft sprockets.

7. I

Install camshaft sprocket bolts to correct torque. Apply new engine oil to bolt threads and seat surface.

Mating mark

Camshaft sprocket (EXH)

SEM905F

SEM906F

EM-45

CYLINDER HEAD

QG

Installation (Cont’d)

8. I

Chain guide

I 9.

Install chain tensioner. Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner. After installing chain tensioner, remove the pin. Install timing chain guide.

Chain tensioner Stopper pin SEM907F

10. Install cylinder head front cover. I Apply liquid gasket to cylinder head front cover. I Use Genuine Liquid Gasket or equivalent.

Cylinder head front cover

2.0 3.0 mm (0.079 0.118 in) dia.

SEM887F

Camshaft position sensor (PHASE)

11. Install camshaft position sensor (PHASE). O-ring

SEM889F

12. Before installing rocker cover, apply a continuous bead of liquid gasket to mating surface of cylinder head. Liquid gasket

3 mm (0.12 in) dia.

Cylinder head Cylinder head front cover

SEM888F

Tighten in numerical order. SEM908F

13. Install rocker cover and tighten bolts in numerical order as shown in the figure. 14. Install spark plugs. 15. Install ignition coils. 16. Install intake manifold rear supports. 17. Install front exhaust tube. 18. Install front undercover. 19. Install air duct to intake manifold collector. 20. Install power steering pulley and pump with bracket. To check power steering fluid, refer to MA section (“Checking

EM-46

CYLINDER HEAD

QG Installation (Cont’d)

Power Steering Fluid and Lines”, “CHASSIS AND BODY MAINTENANCE”). 21. Drive belts. For adjusting drive belt deflection, refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”). 22. Reinstall parts in reverse order of removal.

EM-47

QG

ENGINE REMOVAL Removal and Installation

Removal and Installation SEC. 112

NCEM0022

49 - 59 (5.0 - 6.0, 37 - 43) 16 - 21 (1.7 - 2.1, 12 - 15)

43 - 55 (4.4 - 5.6, 32 - 41)

1 p

43 - 55 (4.4 - 5.6, 32 - 41) 43 - 55 (4.4 - 5.6, 32 - 40)

2 p

30 - 40 (3.1 - 4.0, 23 - 29)

p 5

64 - 74 (6.6 - 7.5, 48 - 54)

62 - 78 (6.4 - 7.9, 46 - 57) .

22 - 28 (2.3 - 2.8, 17 - 20) 60 - 70 (6.2 - 7.1, 45 - 51)

64 - 74 (6.6 - 7.5, 48 - 54)

.

3 p

43 - 55 (4.4 - 5.6, 32 - 41)

43 - 55 (4.4 - 5.6, 32 - 40)

64 - 74 (6.6 - 7.5, 48 - 54)

43 - 55 (4.4 - 5.6, 32 - 40)

6 p

4 p

7 p

43 - 55 (4.4 - 5.6, 32 - 40)

8 p

62 - 78 (6.4 - 7.9, 46 - 57) 60 - 70 (6.2 - 7.1, 45 - 51) 9 p

77 - 98 (7.9 - 9.9, 57 - 72)

77 - 98 (7.9 - 9.9, 57 - 72)

: N·m (kg-m, ft-lb) NEM372

1. 2. 3.

Engine front mounting Cylinder head front mouting bracket Engine front mouting bracket

4. 5. 6.

LH engine mounting Engine rear mounting bracket Engine rear mounting

EM-48

7. 8. 9.

Center member Front mounting bracket Front mounting

ENGINE REMOVAL

QG Removal and Installation (Cont’d)

WARNING: I Position vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled off, otherwise, you may burn yourself and/or fire may break out in fuel line. I Before disconnecting fuel hose, release pressure. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). I Be sure to lift engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: I When lifting engine, be sure to clear surrounding parts. Use special care near accelerator wire casing, brake lines and brake master cylinder. I When lifting the engine, always use engine slingers in a safe manner. I When removing drive shaft, be careful not to damage grease seal of transaxle. I Before separating engine and transaxle, remove crankshaft position sensor (POS) from the cylinder block assembly. I Always be extra careful not to damage edge of crankshaft position sensor (POS), or signal plate teeth. Engine cannot be removed separately from transaxle. Remove engine with transaxle as an assembly.

REMOVAL 1.

NCEM0022S01

Drain coolant from radiator and cylinder block. Refer to (LC) section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). 2. Drain engine oil. 3. Remove battery. 4. Remove coolant reservoir tank and bracket. 5. Remove drive belts. 6. Remove generator and air conditioner compressor from engine. 7. Remove power steering oil pump from engine and position aside. Power steering oil pump does not need to be disconnected from power steering tubes.

EM-49

ENGINE REMOVAL

QG

Removal and Installation (Cont’d)

8. I I I I

I SEM174D

Remove the following parts: RH and LH front tires Undercovers Splash covers RH and LH brake caliper assemblies : 54 - 64 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb) Brake hose does not need to be disconnected from brake caliper assembly. Never depress brake pedal. RH & LH drive shaft. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). When removing drive shaft, be careful not to damage transaxle side grease seal.

I

Disconnect control rod and support rod from transaxle. Control rod: : 14 - 18 N⋅m (1.4 - 1.8 kg-m, 10 - 13 ft-lb) Support rod: : 35 - 47 N⋅m (3.6 - 4.8 kg-m, 26 - 35 ft-lb)

I I I I I

Center member Front exhaust tube Stabilizer bar Cooling fan Radiator

NEM330

.

SEM875DA

I I

Cylinder head front mounting bracket Remove air duct and disconnect wires, harness, pipes, hoses and so on. 9. Lift up engine slightly and disconnect or remove all engine mountings. When lifting engine, be sure to clear surrounding parts. Use special care near brake tubes and brake master cylinder. 10. Remove engine with transaxle as shown. SEM419D

EM-50

QG

ENGINE REMOVAL

Removal and Installation (Cont’d)

Wooden block Jack SEM420D

INSTALLATION I

Install in reverse order of removal.

EM-51

NCEM0022S02

QG

CYLINDER BLOCK Components

Components 83.4 - 93.2 (8.5 - 9.5, 61 - 69)

7.2 - 10.8 (0.73 - 1.10, 63.4 - 95.5) 20.6 - 26.5 (2.1 - 2.7, 15 - 20) O-ring

6.28 - 8.34 (0.64 - 0.85, 55.6 - 73.8)

34.3 - 44.1 (3.50 - 4.50, 25.3 - 32.5)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

7.64 - 9.22 (0.78 - 0.94, 67.7 - 81.6)

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Use Genuine Liquid Gasket or equivalent. : Lubricate with new engine oil. : Do not re-use.

46.1 - 52.0 (4.70 - 5.30, 34.0 - 38.3)

For installation of connecting rod cap, refer to “Assembly”. NEM331

1. 2. 3. 4. 5. 6. 7. 8. 9.

Oil level gauge guide Cylinder block Rear oil seal retainer Rear oil seal Rear plate Flywheel Drain plug Buffle plate Top ring

10. 11. 12. 13. 14. 15. 16. 17.

2nd ring Oil ring Piston Snap ring Piston pin Connecting rod Connecting rod bearing Connecting rod cap

EM-52

18. 19. 20. 21. 22. 23. 24. 25.

Key Main bearing Thrust bearing Crankshaft Main bearing cap Knock sensor Crankshaft position sensor (POS) Signal plate

CYLINDER BLOCK

QG Removal and Installation

Removal and Installation

NCEM0024

CAUTION: I When installing sliding parts such as bearings and pistons, apply engine oil on the sliding surfaces. I Place removed parts, such as bearings and bearing caps, in their proper order and direction. I When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating surfaces. I Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate, and rear plate. I Remove the crankshaft position sensor (POS). I Be careful not to damage sensor edges and single plate teeth.

Disassembly KV10106500

PISTON AND CRANKSHAFT 1. 2. 3.

KV10113300

NCEM0025 NCEM0025S01

Place engine on a work stand. Drain coolant and oil. Remove timing chain. Refer to EM-20.

ST0501S000 SEM927F

Piston heater

Oil

4. I

Remove pistons with connecting rod. When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, if there is no punch mark, install with either side up.

SEM877B

5.

Front

6. I I

Loosen main bearing caps in numerical order as shown in figure. Remove bearing caps, main bearings and crankshaft. Before removing bearing caps, measure crankshaft end play. Refer to EM-61. Bolts should be loosened in two or three steps.

SEM165DB

EM-53

CYLINDER BLOCK

QG

Disassembly (Cont’d)

7.

Remove signal plate from crankshaft.

Crankshaft

Signal plate

SEM928F

Inspection PISTON AND PISTON PIN CLEARANCE

NCEM0026 NCEM0026S01

1.

Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: QG16DE 18.987 - 18.999 mm (0.7474 - 0.7480 in) QG18DE 18.993 - 19.005 mm (0.7478 - 0.7482 in)

2.

Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 18.989 - 19.001 mm (0.7476 - 0.7481 in) Calculate piston pin clearance. QG16DE Dp - dp: -0.004 - 0 (-0.0002 - 0 in) QG18DE Dp − dp: 0.002 - 0.006 (0.0001 - 0.0002 in) If it exceeds the above value, replace piston assembly with pin.

AEM023

3.

Micrometer AEM024

PISTON RING SIDE CLEARANCE NG

NCEM0026S02

Side clearance: Refer to SDS, EM-185 Max. limit of side clearance: Refer to SDS, EM-185 If out of specification, replace piston and/or piston ring assembly.

Feeler gauge OK

Feeler gauge Ring

SEM024AA

PISTON RING END GAP

Piston Press-fit

Feeler gauge Ring

End gap: Refer to SDS, EM-185 Max. limit of ring gap: Refer to SDS, EM-185

Ring

AEM096

EM-54

NCEM0026S03

QG

CYLINDER BLOCK

Inspection (Cont’d)

If out of specification, replace piston ring. If gap exceeds maximum limit with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to SDS, EM-185. I When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

Feeler gauge

NCEM0026S04

Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.3 mm (0.012 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly. SEM150B

Torsion

Feeler gauge

SEM003F

CYLINDER BLOCK DISTORTION AND WEAR

Straightedge Feeler gauge

213.95 - 214.05 mm (8.4232 - 8.4271 in)

SEM486C

NCEM0026S05

Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in figure. Block surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.10 mm (0.004 in) If out of specification, resurface it. The limit for cylinder block resurfacing is determined by the amount of cylinder head resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 213.95 - 214.05 mm (8.4232 - 8.4271 in) If necessary, replace cylinder block.

SEM102F

EM-55

CYLINDER BLOCK

QG

Inspection (Cont’d)

20 (0.79) 60 (2.36) 100 (3.94)

PISTON-TO-BORE CLEARANCE 1.

Unit: mm (in) SEM166D

Front Cylinder bore grade number (1, 2, 3)

2. I

No.2 No.4 No.1 No.3

Cylinder block

NCEM0026S06

Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: Refer to SDS, EM-184 Wear limit: 0.2 mm (0.008 in) Out-of-round (X − Y) standard: Less than 0.015 mm (0.0006 in) Taper (A − B) standard: Less than 0.01 mm (0.0004 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Check for score and seizure. If seizure is found, hone it. If cylinder block or piston is replaced, match piston grade with grade number on cylinder block lower surface.

SEM929F

3.

SEM258C

Measure piston skirt diameter. Piston diameter “A”: Refer to SDS, EM-185. Measuring point “a” (Distance from the top): Refer to SDS, EM-185 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance = Cylinder bore measurement “B” − Piston diameter “A”: Refer to SDS, EM-185 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS EM-185. 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”. Rebored size calculation: D=A+B−C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps and tighten bolts to the specified torque. This will prevent distortion of cylinder bores. 8. Cut cylinder bores. I When any cylinder needs boring, all other cylinders must also be bored. I Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. I Measurement should be done after cylinder bore cools down.

EM-56

CYLINDER BLOCK

QG Inspection (Cont’d)

CRANKSHAFT 1. 2.

Taper: Out-of-round:

NCEM0026S07

Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X − Y): Less than 0.003 mm (0.0001 in) Taper (A − B): Less than 0.004 mm (0.0002 in)

SEM316A

3.

Measure crankshaft runout. Runout (Total indicator reading): Less than 0.04 mm (0.0016 in)

SEM346D

BEARING CLEARANCE I

NCEM0026S08

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

Oil hole

Main bearing 1.

NCEM0026S0801

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

Oil groove Front

SEM366E

2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to EM-52. 3. Measure inner diameter “A” of each main bearing.

Bore gauge

AEM153

4. 5.

.

Measure outer diameter “Dm” of each main journal in crankshaft. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.020 - 0.044 mm (0.0008 - 0.0017 in) Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within standard of any bearing, grind crankshaft journal and use undersized bearing.

AEM026

EM-57

QG

CYLINDER BLOCK Inspection (Cont’d) Main journal and pin journal

I I

When grinding crank pin and crank journal: Grind until clearance is within specified standard bearing clearance. Fillets should be finished as shown in the figure. R: 2.3 2.5 mm (0.091 - 0.098 in) Refer to SDS, EM-187 for standard bearing clearance and available spare parts.

SEM588A

6. Front

a. Main journal grade number (0, 1, 2)

If the crankshaft is replaced, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.

No.1 No.3 No.5 No.2 No.4

Cylinder block

SEM930F

b.

Crankshaft journal grade number No. 1

No. 5

Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals. c. Select main bearing with suitable thickness according to the following table. Main bearing grade color: Crankshaft main journal grade number

AEM172

Oil hole

0

1

2

0

Black

Red

Green

1

Red

Green

Yellow

2

Green

Yellow

Blue

For example: Cylinder block main journal grade number: 1 Crankshaft main journal grade number: 2 Main bearing grade number = 1 + 2 = Yellow

Oil groove Front

Identification colour

Cylinder block main journal grade number

SEM194C

Connecting rod bearing (Big end)

NCEM0026S0802

1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter “C” of each bearing.

Inside micrometer

AEM027

EM-58

QG

CYLINDER BLOCK

Inspection (Cont’d)

4. 5.

Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.014 - 0.039 mm (0.0006 - 0.0015 in) Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing. Refer to step 5, EM-57.

AEM028

I Crankshaft pin journal grade number No. 1

No. 4

If a new bearing, crankshaft or connecting rod is replaced, select connecting rod bearing according to the following table. Connecting rod bearing grade number: These numbers are punched in either Arabic or Roman numerals. Crankshaft pin journal grade number

Connecting rod bearing grade color

0

—

1

Brown

2

Green

SEM437CA

Method B (Using Plastigage) CAUTION: I Do not turn crankshaft or connecting rod while Plastigage is being inserted. I If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance.

EM142

CONNECTING ROD BUSHING CLEARANCE (SmallNCEM0026S09 end) 1.

Measure inner diameter “C” of bushing.

AEM029

2. 3.

Measure outer diameter “Dp” of piston pin. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C − Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.023 mm (0.0009 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston pin.

Micrometer AEM030

EM-59

CYLINDER BLOCK

QG

Inspection (Cont’d)

REPLACEMENT OF CONNECTING ROD BUSHING (Small end) NCEM0026S10 1.

Align. SEM062A

Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. Ream the bushing so that clearance with piston pin is within specification. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

FLYWHEEL/DRIVE PLATE RUNOUT Dial gauge

NCEM0026S12

Runout (Total indicator reading): Flywheel Less than 0.15 mm (0.0059 in) CAUTION: I Do not allow any magnetic materials to contact the ring gear teeth and rear plate. I Do not resurface flywheel. Replace as necessary. SEM931F

Assembly PISTON

NCEM0027 NCEM0027S01

1.

Install new snap ring on one side of piston pin hole.

2.

Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.

SEM166B

Piston pin grade number

Piston grade number

Oil hole Cylinder number

Front mark

I I I

Front

SEM932F

Punchmark side up (if mark is present.)

3.

Set piston rings as shown.

CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original position. I Install new piston rings either side up if there is no punch mark.

SEM965E

EM-60

CYLINDER BLOCK

QG Assembly (Cont’d)

Oil ring expander

Top ring Oil ring upper rail

I

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

Engine front

Oil ring lower rail

2nd ring

SEM160B

CRANKSHAFT 1. 2.

Signal plate

Duel pin

I I

NCEM0027S02

Install signal plate to crankshaft. Set main bearings in their proper positions on cylinder block and main bearing cap. Confirm that correct main bearings are selected by using Method A or Method B. Refer to EM-57. Apply new engine oil to bearing surfaces.

Crankshaft

SEM934F

Oil hole

Oil groove Front

SEM366E

Identification No. Cap

Engine front

SEM420C

3.

Engine front

I I I I Tighten in numerical order.

Install crankshaft and main bearing caps and tighten bolts to the specified torque. Apply new engine oil to the bolt thread and seat surface. Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing caps. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown in figure. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

SEM933F

EM-61

CYLINDER BLOCK

QG

Assembly (Cont’d)

4.

Measure crankshaft end play. Crankshaft end play: Standard 0.060 - 0.260 mm (0.0024 - 0.0102 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace thrust bearing with new ones.

SEM116F

5.

Align oil hole.

I I I

Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to EM-58. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bolt threads and bearing surfaces.

SEM168D

6. a. I I

Piston ring compressor EM03470000

I I

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

SEM942F

b. KV10112100

I I

Install connecting rod caps. Apply new engine oil to bolt threads and nut seating surfaces. Tighten connecting rod cap nuts in the following procedure: Tighten to 13.72 to 15.68 N⋅m (1.399 to 1.599 kg-m, 10.120 - 11.566 ft-lb). Turn nuts to 35° to 40° degrees clockwise with an angle wrench. If an angle wrench is not available, tighten nuts to 23 to 28 N⋅m (2.3 to 2.9 kg-m, 17 to 21 ft-lb).

SEM943F

7.

Feeler gauge

Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.200 - 0.470 mm (0.0079 - 0.0185 in) Limit 0.5 mm (0.0205 in) If beyond the limit, replace connecting rod and/or crankshaft.

SEM935F

EM-62

CYLINDER BLOCK

QG Assembly (Cont’d)

Apply liquid gasket.

8. a. b.

.

Rear oil seal retainer

2.0 - 3.0 mm (0.079 - 0.118 in) dia.

I I 9.

Install rear oil seal retainer. Before installing rear oil seal retainer, remove old liquid gasket from cylinder block and retainer. Apply a continuous bead of liquid gasket to rear oil seal retainer. Use Genuine Liquid Gasket or equivalent. Apply around inner side of bolt holes. Install crankshaft positon sensor (POS).

AEM248

Engine front

10. Install knock sensor.

SEM936F

EM-63

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING SR20DE

Camshaft bearing noise

Rocker noise

Timing chain and chain tensioner noise

VALVE MECHANISM TIMING CHAIN Valve

Water pump noise

Piston pin noise ROTATION MECHANISM DRIVE BELT Drive belt noise (stick/slipping)

Piston slap noise

Connecting rod bearing noise

Drive belt noise (stick/slipping) Main bearing noise NEM335

EM-64

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING SR20DE NVH Troubleshooting — Engine Noise

NVH Troubleshooting — Engine Noise Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise

Top of Engine rocker cover Cylinder head

Type of noise

When starting

When idling

When While racing driving

Source of noise

Front of engine Timing chain cover

Front of Engine

Reference page

C

A

—

A

B

—

Rocker noise

Hydraulic lash adjuster

EM-96

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-92

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-110, 116

A

Piston slap noise

Piston-to-bore clearance Piston ring side clearance EM-111, 112 Piston ring end gap Connecting rod bend and torsion Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)

EM-115, 116

Main bearing oil clearance Crankshaft runout

EM-113, 114

—

Slap or rap

A

A

—

—

—

B

B

B

B

Cylinder block (Side of Engine) Oil pan

Check item

Ticking or clicking

Slap or knock

Crankshaft Pulley

Before After warm- warmup up

Knock

A

B

C

B

B

B

Connecting rod-bearing noise

Knock

A

B

—

A

B

C

Main bearing noise

B

Timing chain and Timing chain cracks and chain tenwear sioner noise

Drive belt deflection

Idler pulley bearing operation

Tapping or ticking

A

A

—

B

B

Squeak or fizzing

A

B

—

B

—

C

Other drive belts (sticking or slipping)

Creaking

A

B

A

B

A

B

Other drive belts (slipping)

Squall or creak

A: Closely related

B: Related

A

B

—

C: Sometimes related

B

A

—: Not related

EM-65

B

Water pump Water pump operation noise

EM-132

MA Section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) LC Section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)

SR20DE

OUTER COMPONENT PARTS SEC. 130⋅140⋅150⋅210⋅211⋅221 13 - 16 (1.3 - 1.6, 9 - 12)

Refer to “Installation” in “TIMING CHAIN”. Washer 16 - 21 (1.6 - 2.1, 12 - 15)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Insulator Gasket

Gasket Gasket 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

16 - 22 (1.6 - 2.2, 12 - 16) .

41 - 52 (4.2 - 5.3, 30 - 38)

18 - 21 (1.8 - 2.1, 13 - 15)

21 - 26 (2.1 - 2.7, 15 - 20)

.

16 - 21 (1.6 - 2.1, 12 - 15)

45 - 60 (4.6 - 6.1, 33 - 44)

16 - 21 (1.6 - 2.1, 12 - 15)

16 - 21 (1.6 - 2.1, 12 - 15)

16 - 22 (1.6 - 2.2, 12 - 16)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) ★

16 - 19 (1.6 - 1.9, 12 - 14) ★

15 - 21 (1.5 - 2.1, 11 - 15)

16 - 19 (1.6 - 1.9, 12 - 14)

Oil seal 3.7 - 5.0 (0.38 - 0.51, 33.0 - 44.3)

16 - 21 (1.6 - 2.1, 12 - 15) : Do not re-use.

N·m (kg-m, ft-lb)

: Lubricate with new engine oil.

N·m (kg-m, in-lb) ★

Apply liquid gasket.

1 p 2 p 3 p 4 p 5 p

Oil filler cap Rocker cover PCV valve Camshaft position sensor, ignition coil and power transistor built into distributor Intake manifold supports

6 p 7 p 8 p 9 p 10 p 11 p

: Refer to LC section. (“Thermostat”, “ENGINE COOLING SYSTEM”).

Knock sensor Oil filter bracket Oil catcher Oil filter Water pipe assembly Thermostat housing

EM-66

12 p 13 p 14 p 15 p 16 p 17 p

NEM373

Air relief plug Thermostat Water inlet Starter motor Power steering oil pump adjusting bar Power steering oil pump bracket

SR20DE

OUTER COMPONENT PARTS SEC. 140⋅147⋅163⋅164

2.9 - 3.8 (0.30 - 0.39, 26.0 - 33.9)

O-ring

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

1st 9 - 11 (1.0 - 1.1, . 7.0 - 8.0) 2nd 21 - 26 (2.2 - 2.6, 16.0 - 19.0)

✩

O-ring

Clip 6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2)

Gasket

6.9 - 9.5 (0.70 - 0.97, 60.8 - 84.2) Gasket

Gasket 2.0 - 2.5 (0.20 - 0.26, 17.4 - 22.6)

Gasket

18 - 21 (1.9 - 2.2, 13.3 - 15.4)

3.0 - 4.0 (0.31 - 0.41, 26.9 - 35.6)

✩ Throttle body bolts tightening procedure 1) Tighten all bolts to 9 to 11 N·m (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb) 2) Tighten all bolts to 18 to 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

18 - 21 (1.9 - 2.2, 13.3 - 15.4)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) ü : Do not re-use

Tighten in numerical order.

NEM337

1 p 2 p 3 p

Injector Pressure regulator IACV-AAC valve

4 p 5 p 6 p

Canister purge control valve Injector tube Throttle body

EM-67

7 p 8 p

Throttle position sensor Intake manifold

SR20DE

OUTER COMPONENT PARTS SEC. 118⋅140⋅230⋅275

Gasket

5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.3)

8 - 12 (0.8 - 1.2, 64 - 104)

40 - 50 (4.1 - 5.1, 30.0 - 36.8) 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 45 - 60 (4.6 - 6.1, 33 - 44) 37 - 48 (7.8 - 4.9, 27.3 - 35.4)

45 - 60 (4.6 - 6.1, 33 - 44)

44 - 52 (4.5 - 5.3, 32.5 - 38.3)

16 - 22 (1.6 - 2.2, 12 - 16)

16 - 22 (1.6 - 2.2, 12 - 16)

39 - 46 (4.0 - 4.7, 28.8 - 33.9)

16 - 22 (1.6 - 2.2, 12 - 16)

45 - 60 (4.6 - 6.1, 33 - 44)

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket.

16 - 22 (1.6 - 2.2, 12 - 16)

: Do not re-use

1 p 2 p 3 p 4 p

Oil level gauge Alternator adjusting bar Compressor bracket Alternator bracket

NEM339 5 p 6 p 7 p 8 p

Water outlet Drain plug Exhaust manifold Heated oxygen sensor

EM-68

9 p 10 p 11 p

Exhaust manifold cover Blow-by hose Catalytic convertor

SR20DE

COMPRESSION PRESSURE

Measurement of Compression Pressure

Measurement of Compression Pressure 1. 2. 3. 4. 5.

6. 7. 8. 9. I

Warm up engine. Turn ignition switch off. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC-section. Remove all spark plugs. Disconnect distributor center cable.

Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. Crank engine and record highest gauge indication. Repeat the measurement for each cylinder. Always use a fully-charged battery to obtain specified engine revolution.

Compression pressure: kPa (bar, kg/cm2, psi)/300 rpm

SEM968C

Standard

1,275 (12.75, 13.0, 185)

Minimum

1,079 (10.79, 11.0, 156)

Difference limit between cylinders 20 mm (0.79 in) dia

Compression tester rubber adaptor diameter should be less than 20 mm (0.79 in) to prevent fouling with cylinder head.

NEM118

98 (0.98, 1.0, 14)

10. If cylinder compression in one or more cylinders is low: A: pour a small amount of engine oil into cylinders through spark plug holes. B: retest compression. I If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston condition. I If pressure stays low, a valve may be sticking or seating badly. Inspect and repair valve and valve seat. (Refer to SDS). If valve or valve seat is damaged excessively, replace them. I If compression stays low in two cylinders that are next to each other: A. The cylinder head gasket may be leaking, or B. Both cylinders may have valve component damage. Inspect and repair as necessary.

EM-69

SR20DE

OIL PAN Removal

SEC. 110 Refer to “Installation”. 1 p

Refer to “Installation”.

p 2

6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0)

5 p

3 p

29 - 39 (3.0 - 4.0, 22 - 29)

1 Aluminum oil pan p 2 Rear cover plate p 3 Drain plug p 4 Steel oil pan p 5 p Baffle plate

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket.

Washer üü

üü: Do not re-use

6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0) Refer to “Installation”.

4 p

6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)

NEM217

Removal

9 p

11 p

Remove engine under cover. Drain engine oil.

3.

Remove steel oil pan bolts.

4. a. I I

Remove steel oil pan. Insert Tool between aluminum oil pan and steel oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed.

7 p

4 p

Engine front

1. 2.

3 p

2 p

1 p 8 6 p p

Loosen in numerical order.

10 p

5 p

NEM218

SEM602E

EM-70

OIL PAN

SR20DE Removal (Cont’d)

b. c.

Slide Tool by tapping on the side of the Tool with a hammer. Remove steel oil pan.

d.

Remove baffle plate.

5. 6. 7.

Remove front exhaust tube. Set a suitable transmission jack under transaxle and hoist engine with engine slinger. Remove center member.

8.

Remove compressor gussets.

9.

Remove rear cover plate.

SEM603E

.

Engine front

.

Baffle plate NEM219

Center member Transmission jack SEM045D

Front compressor gusset

Compressor bracket Rear compressor . SEM048D gusset

Rear cover plate

SEM043D

EM-71

OIL PAN

SR20DE

Removal (Cont’d)

10. Remove aluminum oil pan bolts.

Engine front

Loosen in numercal order.

SEM044D

11. Remove the two engine-to-transaxle bolts and install them into open bolt holes shown. Tighten the bolts to release aluminum oil pan from cylinder block.

SEM783E

12. a. I I

Remove aluminum oil pan. Insert Tool between cylinder block and aluminum oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be damaged.

b.

Slide Tool by tapping on the side of the Tool with a hammer.

SEM046D

SEM047D

13. Remove the two engine-to-transaxle bolts previously installed in aluminum oil pan.

SEM223D

EM-72

OIL PAN

SR20DE Installation

Installation 1. a. I

Install aluminum oil pan. Before installation use a scraper to remove all traces of liquid gasket from mating surfaces. Also remove traces of liquid gasket from mating surface of cylinder block and front cover.

SEM050D

b. Cut here.

I I

7 mm (0.28 in)

Liquid gasket

I

Groove

Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). Attaching should be done within 5 minutes after coating.

Bolt hole SEM357E

I

For areas marked with “★”, apply liquid gasket to the outer side of the bolt hole.

c. I

Install aluminum oil pan. Install bolts in the reverse order of removal. 1 - p 16 bolts: p : 16 - 19 N·m (1.6 - 1.9 kg-m, 12 - 14 ft-lb) 17 , p 18 bolts: p : 8.14 - 9.51 N·m (0.830 - 0.970 kg-m, 72.05 84.77 in-lb)

2.

Install the two engine to transaxle bolts. : 30 - 40 N·m (3.1 - 4.1 kg-m, 22 - 30 ft-lb) Install rear cover plate.

4.0 - 5.0 mm (0.157 - 0.197 in)

Tube presser

Liquid gasket

.

SEM065D

Engine front

Tighten in numerical order. SEM052D

3.

Install

Install

SEM224D

EM-73

OIL PAN

SR20DE

Installation (Cont’d)

Front compressor gusset

4. 5. 6. 7.

Install Install Install Install

compressor gussets. center member. front exhaust tube. baffle plate.

8. a.

Install steel oil pan. Before installation, use a scraper to remove all traces of liquid gasket from mating surfaces. Also remove traces of liquid gasket from mating surface of aluminum oil pan.

Compressor bracket

Rear compressor gusset SEM363D Tighten in numerical order.

I

NEM220

b.

Cut here. 7 mm (0.28 in)

I I

Liquid gasket Inner side

Groove

I

Apply a continuous bead of liquid gasket to mating surface of steel oil pan. Use Genuine Liquid Gasket or equivalent. Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). Attaching should be done within 5 minutes after coating.

Bolt hole SEM015E

Liquid gasket

4.0 - 5.0 mm (0.157 0.197 in)

NEM221

5 p

8 p

Engine front

c. I

1 p

3 p

I

Install steel oil pan. Tighten bolts in numerical order as shown together with heated oxygen sensor harness bracket. Wait at least 30 minutes before refilling engine oil.

9 p 10 p

11 p 6 p

4 p

2 p

7 p

NEM222

EM-74

SR20DE

TIMING CHAIN

Components

Components

SEM718EC 1 p 2 p 3 p 4 p

Cylinder block Upper chain guide Intake camshaft sprocket Chain tensioner

5 p 6 p 7 p 8 p

Chain guide Front cover Crank pulley Oil pump spacer

EM-75

9 p 10 p 11 p 12 p

Crankshaft sprocket Chain guide Timing chain Exhaust camshaft sprocket

TIMING CHAIN

SR20DE

Components (Cont’d)

CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley.

Removal 1. 2. 3.

Rocker cover

4. 5. I I I I

6. 7.

Remove rocker cover bolts in numerical order. Remove rocker cover.

8.

Remove cylinder head outside bolts.

Engine front

Loosen in numerical order.

NLEM0126

Remove engine under cover. Remove front RH wheel and engine side cover. Drain coolant by removing cylinder block drain plug and lower radiator hose. Refer to MA-29, “Changing Engine Coolant”. Remove drive belts and water pump pulley. Disconnect the following parts: Vacuum hoses Wires Harness Connectors

SEM029G

Front cover

SEM287G

EM-76

SR20DE

TIMING CHAIN

Removal (Cont’d)

9.

Set No. 1 piston at TDC of its compression stroke.

I

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure.

SEM983C

SEM695DA

10. Remove oil pans. Refer to EM-70, “Oil Pan”.

11. Remove oil strainer. 12. Temporarily install center member to support engine.

SEM038G

13. 14. 15. 16. 17.

Suitable puller

Remove crankshaft pulley. Remove generator. Remove A/C compressor and position it to the side. Remove A/C bracket. Remove generator bracket.

SEM980C

EM-77

TIMING CHAIN

SR20DE

Removal (Cont’d)

18. Set a suitable transmission jack under main bearing beam.

Engine front

Transmission jack SEM039G

19. Remove RH engine mounting.

RH engine mounting SEM040G

RH engine mounting bracket

20. Remove RH engine mounting bracket.

Water pump

SEM041G

21. Remove oil pump drive spacer. CAUTION: Be careful not to damage oil pump drive spacer and front oil seal. 22. Remove front cover. CAUTION: I Be careful not to tear or damage the cylinder gasket. I Inspect for oil leakage at front oil seal. Replace seal if oil leak is present. SEM721E

23. Remove chain tensioner.

Chain tensioner

.

SEM032G

EM-78

TIMING CHAIN

SR20DE Removal (Cont’d)

24. Remove timing chain guides.

SEM982CA

25. Remove camshaft sprockets. I For retiming, apply paint mark to timing chain matched with mating marks of camshaft sprockets. 26. Remove timing chain and crankshaft sprocket.

SEM034G

Inspection

NLEM0127

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

SEM984C

Installation

Engine front

NLEM0128

1. I

Install crankshaft sprocket on crankshaft. Make sure mating marks on crankshaft sprocket face front of engine.

2.

Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 oclock. Fit timing chain on crankshaft sprocket, aligning the mating marks.

Crankshaft side

Crankshaft sprocket SEM470E

SEM985C

EM-79

TIMING CHAIN

SR20DE

Installation (Cont’d) 20 rollers

I

Mating mark color on timing chain. 1: Golden 2, 3: White

3.

Install timing chain and timing chain guides.

4.

Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.

Mating mark

Mating mark

56 rollers

48 rollers

Mating mark SEM500E

SEM982CA

Mating mark

Mating mark

Mating mark

.

Mating mark

.

RH camshaft sprocket

LH camshaft sprocket SEM048G

I

Lock camshafts as shown in figure and tighten to specified torque. : 137 - 157 N⋅m (14.0 - 16.0 kg-m, 101 - 116 ft-lb) Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.

SEM049G

EM-80

TIMING CHAIN

SR20DE Installation (Cont’d)

5. Install chain tensioner. Make sure the camshaft sprockets are tightened completely. Press cam stopper down and press-in sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow A points toward engine front.

SEM990C

SEM991C

6. I

Use a scraper to remove old liquid gasket from mating surface of front cover. Also remove old liquid gasket from mating surface of cylinder block.

SCL491A

7. 2.0 - 3.0 mm

I

Apply a continuous bead of liquid gasket to front cover. Also apply liquid gasket to matching surface to cylinder head gasket. Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent. Be sure to install new front oil seal in the right direction. Refer to EM-84, “FRONT OIL SEAL”.

8. 9.

Install oil pump drive spacer. Install front cover.

Never apply liquid gasket to this groove.

BEM010

SEM721E

EM-81

TIMING CHAIN Installation (Cont’d)

I

Wipe off excessive liquid gasket.

Wipe off liquid gasket SEM042G

10. Install cylinder head outside bolts.

Front cover

SEM287G

11. Install RH engine mounting and bracket. 12. Install generator bracket and generator. 13. Install A/C compressor bracket and compressor.

RH engine mounting SEM040G

14. Install crankshaft pulley. 15. Set No. 1 piston at TDC of its compression stroke.

Crankshaft pulley

.

SEM073D

16. Install oil strainer. 17. Install oil pans. Refer to EM-70, “Oil Pan”.

SEM038G

EM-82

SR20DE

TIMING CHAIN

SR20DE Installation (Cont’d)

(0.39)

Engine front Unit: mm (in)

18. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head. 19. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations. I Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.

(0.39) 3 (0.12) BEM006

3 mm (0.12 in) dia.

SEM051G

Rocker cover

Engine front

Tighten in numerical order.

SEM052G

20. Install rocker cover and oil separator. I Be sure to install washers between bolts and rocker cover. I Tightening procedure STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order. STEP 2: Tighten bolts 1 - 13 in that order. : 8 - 10 N⋅m (0.8 - 1.0 kg-m, 69 - 87 in-lb) 21. Install the following parts: I Spark plugs and leads I Water pump pulley and drive belts. For adjusting drive belt deflection, refer to MA-28, “Checking Drive Belts”. I Refit lower radiator hose and cylinder block drain plug. I Refill with engine coolant. Refer to MA-29, “Changing Engine Coolant”. I Front RH wheel I Engine under cover 22. Connect the following: I Vacuum hoses I Wire harnesses and connectors

EM-83

OIL SEAL REPLACEMENT

SR20DE

VALVE OIL SEAL 1. 2. 3. 4. 5.

SEM077D

6.

Remove accelerator cable. Remove rocker cover and oil separator. Remove camshafts and sprockets. Refer to “Removal” in “CYLINDER HEAD” (EM-87). Remove spark plugs. Install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (4.9 bar, 5 kg/cm2, 71 psi). Remove rocker arm, rocker arm guide and shim.

7. Remove valve spring with Tool. Piston concerned should be set at TDC to prevent valve from falling.

Attachment Compressor assembly SEM604E

8.

Remove valve oil seal.

9.

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

10.7 mm (0.421 in)

SEM994C

KV10115600

SEM358E

FRONT OIL SEAL 1. I I I I 2. Be

Remove the following parts: Engine undercover Front RH wheel and engine side cover Drive belts Crankshaft pulley Remove front oil seal. careful not to scratch front cover.

SEM997C

EM-84

OIL SEAL REPLACEMENT

Engine inside

Oil seal lip

SR20DE

I

Install new oil seal in the direction shown.

3.

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

Engine outside

Dust seal lip

SEM715A

SEM998C

REAR OIL SEAL 1. 2. 3. I

Remove transaxle. (Refer to MT or AT section.) Remove flywheel or drive plate. Remove rear oil seal. Be careful not to scratch rear oil seal retainer.

I

Install new oil seal in the direction shown.

4.

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

SEM999C

Engine inside

Oil seal lip

Engine outside

Dust seal lip

SEM715A

Suitable tool SEM001D

EM-85

SR20DE

CYLINDER HEAD Components

Components .

NLEM0130

SEC. 111⋅130

Refer to “Installation” in “CYLINDER HEAD”. Washer Intake side Rocker cover gasket

Refer to “Installation” in “CYLINDER HEAD”. Exhaust side

Gasket

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Valve oil seal

O-ring Refer to LC section (“Water Outlet”, “ENGINE COOLING SYSTEM”).

Gasket

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 9.0 - 11.8 (0.92 - 1.2, 79.9 - 104.2)

Refer to “Installation” in “CYLINDER HEAD”. Refer to “Installation” in “CYLINDER HEAD”.

N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Apply Genuine RTV Silicone SEALANT Part No. 999 MP-A7007 or equivalent.

137 - 157 (14 - 16, 101 - 116)

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

Oil filler cap Rocker cover Rocker arm guide Rocker arm Shim Hydraulic lash adjuster Chain tensioner

8. 9. 10. 11. 12. 13.

Lubricate with new engine oil.

Camshaft sprocket Camshaft Camshaft bracket Water outlet Cylinder head Valve

EM-86

14. 15. 16. 17. 18. 19.

Valve spring seat Valve spring Valve spring retainer Valve collet Spark plug Cylinder head bolt

NEM355

CYLINDER HEAD

SR20DE Removal

Removal 1. 2. 3. 4. 5. 6. 7. I I I I I I 8.

Rocker cover

9. Remove rocker cover bolts in numerical order. 10. Remove rocker cover.

Engine front

Loosen in numerical order.

SEM029G

11. Remove intake manifold supports. Intake manifold supports

SEM030G Intake manifold

NLEM0131

Release fuel pressure. Refer to EC-SR-31, “Fuel Pressure Release”. Remove engine under covers. Remove front RH wheel and engine side cover. Drain coolant by removing cylinder block drain plug and radiator drain cock. Refer to MA-29, “Changing Engine Coolant”. Remove radiator. Remove air duct to intake manifold. Disconnect the following parts: Vacuum hoses Fuel hoses Wires Harness Connectors Front exhaust tube Remove all spark plugs.

12. Remove water pipe assembly.

SEM065G

EM-87

CYLINDER HEAD

SR20DE

Removal (Cont’d)

13. Set No. 1 piston at TDC of its compression stroke.

SEM983C

Mating mark

Mating mark

I

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure.

LH camshaft sprocket RH camshaft sprocket SEM031G

14. Remove chain tensioner.

Chain tensioner

.

SEM032G Rotor head position (No. 1 cylinder at TDC)

15. Remove distributor. Do not turn rotor with distributor removed.

SEM033G

16. Remove camshaft sprockets. I For retiming in cylinder head removal, apply paint mark to timing chain matched with mating marks of camshaft sprockets.

SEM034G

EM-88

CYLINDER HEAD

SR20DE Removal (Cont’d)

RH camshaft

Camshaft bracket

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

Engine front

LH camshaft Loosen in numerical order.

SEM035G

18. 19. I I

Remove starter motor. Remove the following water hoses: Water hose for cylinder block. Water hoses for heater.

SEM036G

20. Remove cylinder head outside bolts. Water inlet

Water outlet

SEM037G

21. Remove cylinder head bolts in numerical order. I Removing bolts in incorrect order could result in a warped or cracked cylinder head. I Loosen cylinder head bolts in two or three steps. 22. Remove cylinder head completely with intake and exhaust manifolds.

SEM978C

Disassembly OK

NG

SEM878CA

CAUTION: I When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting surfaces with new engine oil. I When tightening cylinder head bolts, camshaft sprocket bolts, cramshaft pulley bolt and seat surfaces, lubricate with new engine oil. I If a hydraulic lash adjuster is kept on its side, there is a risk of air entering it. After removal, always set hydraulic

EM-89

CYLINDER HEAD

SR20DE

Disassembly (Cont’d)

lash adjuster straight up, or keep it soaked in new engine oil. I Do not disassemble hydraulic lash adjusters. I Attach tags to lash adjusters so as not to mix them up. 1. Remove rocker arms, shims, rocker arm guides and hydraulic lash adjusters from cylinder head. CAUTION: Keep parts in order so that they can be installed in their original positions during assembly.

Rocker arm guide Rocker arm Shim Hydraulic lash adjuster

SEM202D

2. 3.

Remove exhaust manifold cover. Remove exhaust manifold.

4.

Remove water outlet.

5.

Remove intake manifold.

6.

Remove thermostat housing with water pipe.

Loosen in numerical order. SEM059G

Water outlet

.

SEM082D

Loosen in numerical order.

SEM061G

Thermostat housing

Water pipe NEM215

EM-90

CYLINDER HEAD

SR20DE Inspection

7.

Remove valve components with Tool.

8.

Remove valve oil seal with a suitable tool.

Attachment Compressor assembly SEM604E

SEM994C

Inspection CYLINDER HEAD DISTORTION

SEM925C

Head surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface. Resurfacing limit: The limit of cylinder head is determined by the cylinder block resurfacing in an engine. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: 136.9 - 137.1 mm (5.390 - 5.398 in)

CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.

EM-91

CYLINDER HEAD

SR20DE

Inspection (Cont’d)

CAMSHAFT RUNOUT 1.

2.

Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.

SEM926C

CAMSHAFT CAM HEIGHT 1.

SEM549A

2.

Measure camshaft cam height. Standard cam height: Intake 37.775 mm (1.4872 in) Exhaust 37.404 mm (1.4726 in) Cam wear limit: Intake & Exhaust 0.2 mm (0.008 in) If wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE 1. 2.

Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: 28.000 - 28.021 mm (1.1024 - 1.1032 in)

SEM927C

3.

4.

.

SEM012A

Measure outer diameter of camshaft journal. Standard outer diameter: 27.950 - 27.970 mm (1.1004 - 1.1012 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard 0.030 - 0.071 mm (0.0012 - 0.0028 in) Limit 0.15 mm (0.0059 in)

EM-92

SR20DE

CYLINDER HEAD

Inspection (Cont’d)

CAMSHAFT END PLAY 1. 2.

Install camshaft in cylinder head. Measure camshaft end play. Camshaft end play: Standard 0.055 - 0.139 mm (0.0022 - 0.0055 in) Limit 0.20 mm (0.0079 in)

SEM002D

CAMSHAFT SPROCKET RUNOUT 1. 2.

3.

Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.25 mm (0.0098 in) If it exceeds the limit, replace camshaft sprocket.

SEM929C

VALVE GUIDE CLEARANCE 1.

Measure valve deflection in a parallel direction with rocker arm. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 in)

2. a. b.

If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance: Standard Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in) Limit Intake 0.08 mm (0.0031 in) Exhaust 0.1 mm (0.004 in) If it exceeds the limit, replace valve or valve guide.

Approx. 15 mm (0.59 in)

SEM003D

Micrometer

SEM938C

c.

EM-93

CYLINDER HEAD

SR20DE

Inspection (Cont’d) Oil

VALVE GUIDE REPLACEMENT 1.

To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).

2.

Press out valve guide or use a hammer and suitable tool.

3.

Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake: 10.175 - 10.196 mm (0.4006 - 0.4014 in) Exhaust: 10.175 - 10.196 mm (0.4006 - 0.4014 in)

4.

Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head. Projection “L”: 14.0 - 14.2 mm (0.551 - 0.559 in)

5.

Ream valve guide. Valve guide inner diameter: Intake: 6.000 - 6.018 mm (0.2362 - 0.2369 in) Exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

SEM008A

SEM931C

Suitable reamer

.

SEM932C

SEM083D

Suitable reamer

.

SEM932C

EM-94

CYLINDER HEAD

SR20DE Inspection (Cont’d)

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

SEM934C

REPLACING VALVE SEAT FOR SERVICE PARTS .

1. Recess diameter

SEM795A

Oil

Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 35.500 - 35.516 mm (1.3976 - 1.3983 in) Exhaust 31.500 - 31.516 mm (1.2402 - 1.2408 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. 3. Heat cylinder head to 110 to 130°C (230 to 266°F). 4. Press fit valve seat until it seats on the bottom.

SEM008A

5. 6. 7.

SEM892B

Cut or grind valve seat using a suitable tool at the specified dimensions as shown in SDS (EM-190). After cutting, lap valve seat with abrasive compound. Check valve seating condition. Seat face angle “α”: 44°53′ - 45°07′ Contacting width “W”: Intake 1.385 - 1.401 mm (0.0545 - 0.0552 in) Exhaust 1.385 - 1.401 mm (0.0545 - 0.0552 in)

VALVE DIMENSIONS

T (Margin thickness)

Check dimensions in each valve. For dimensions, refer to SDS (EM-189). When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

.

SEM188A

EM-95

CYLINDER HEAD

SR20DE

Inspection (Cont’d) S (Out-of-square)

VALVE SPRING Squareness 1.

2.

Measure “S” dimension. Out-of-square: Less than 2.2 mm (0.087 in) If it exceeds the limit, replace spring. Free height Check free height: 49.36 mm (1.9433 in)

SEM288A

Pressure Check valve spring pressure. Pressure: N (kg, lb) at height mm (in) Standard 519 - 571 (52.9 - 58.2, 116.6 - 128.3) at 27 (1.063) Limit Replace if load is less than 501 (51.1 - 112.7) at 27 (1.063) EM113

HYDRAULIC LASH ADJUSTER 1.

Check contact and sliding surfaces for wear or scratches.

2.

Check diameter of lash adjuster. Outer diameter: 16.980 - 16.993 mm (0.6685 - 0.6690 in)

3.

Check lash adjuster guide inner diameter. Inner diameter: 17.000 - 17.020 mm (0.6693 - 0.6701 in) Standard clearance between lash adjuster and adjuster guide: 0.007 - 0.040 mm (0.0003 - 0.0016 in)

SEM935C

SEM936C

.

SEM084D

EM-96

CYLINDER HEAD

SR20DE Assembly

ROCKER ARM, SHIM AND ROCKER ARM GUIDE Bearing surface

Rocker arm

Check contact and sliding surfaces of rocker arms, shims and rocker arm guides for wear or scratches.

Shim

Rocker arm guide

NEM144

Assembly

Tighten in numerical order.

1.

Install intake manifold.

2. I 1) 2) 3) 4)

Install thermostat housing with water pipe. Tightening procedure: A to 2 - 5 N·m (0.2 - 0.5 kg-m, 1.4 - 3.6 ft-lb). Tighten bolt p Tighten bolt p C to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). A to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). Tighten bolt p B to 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb). Tighten bolt p

3. 4.

Install exhaust manifold. Install exhaust manifold cover.

5. a.

Install water outlet. Before installing water outlet, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder head. Apply a continuous bead of liquid gasket to mating surface of water outlet. Use Genuine Liquid Gasket or equivalent. Install valve component parts. Install valves with larger diameter head on the intake side.

SEM064G

Thermostat housing

Water pipe NEM216

Tighten in numerical order. SEM059GA

I 2.0 - 3.0 mm (0.079 - 0.118 in)

Liquid gasket SEM086D

b. I 6. I

EM-97

CYLINDER HEAD

SR20DE

Assembly (Cont’d)

I I I

Wide pitch

I Narrow pitch

Always use new valve oil seal. Refer to OIL SEAL REPLACEMENT. Before installing valve oil seal, install valve spring seat. Install valve spring (uneven pitch type) with its narrow pitched side toward cylinder head side (paint mark). After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.

Paint mark SEM085D

Cylinder head side

7. a. Push

Check hydraulic lash adjusters. Push rocker arm at hydraulic lash adjuster location, and see if rocker arm moves. If it moves at least 1 mm (0.04 in), it indicates that there is air in the high pressure chamber. Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.

NEM146

b.

Rod

Engine oil

Remove hydraulic lash adjuster and dip in a container filled with engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves. Air cannot be bled from this type of lash adjuster by running the engine.

NEM147

8.

Install rocker arms, shims, rocker arm guides and hydraulic lash adjusters. CAUTION: Install all parts in their original positions.

Rocker arm guide Rocker arm Shim Hydraulic lash adjuster

SEM202D

9. Shim Rocker arm guide Valve collet

a. I

Valve spring retainer Valve spring

Select a suitable shim when replacing any of the following parts with a new one: Cylinder head, shim, rocker arm guide and valve seat. Proceed as follows to select the shim of correct thickness. Install valve component parts to cylinder head (Except shim). Always replace rocker arm guide with a new one.

Valve spring seat Valve oil seal Valve SEM364D

EM-98

CYLINDER HEAD

SR20DE Assembly (Cont’d)

Dial gauge

b. c.

Remove hydraulic lash adjuster. Install Tool* into hydraulic lash adjuster fixing hole. * Tool (KV10115700) is screwed into magnetic stand rod used with dial gauge.

Rod

SEM365DA

SEM899D

d.

Make sure that the following parts are installed to the cylinder head: Valve, valve spring, collet, retainer and rocker arm guide (except shim). Measure difference (T1) between sliding surface of rocker arm guide and valve stem end on shim side. When measuring, lightly pull dial indicator rod toward you to eliminate play in Tool (KV10115700).

e.

I

Shim

Select correct shim. Shim thickness (T): T1 ± 0.025 mm (0.0010 in) Shims are available in different thicknesses from 2.800 mm (0.1102 in) to 3.200 mm (0.1260 in) in increments of 0.025 mm (0.0010 in).

Indicate T = 2.800 mm (0.1102 in) SEM096D

Installation 1.

2.0 - 3.0 mm (0.079 - 0.118 in) dia.

NLEM0136

Before installing cylinder head gasket, apply liquid gasket as shown in the illustration.

Liquid gasket AEM250

EM-99

CYLINDER HEAD

SR20DE

Installation (Cont’d)

2.

SEM390G

Install cylinder head completely with intake and exhaust manifolds. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones. Limit (d1 − d2): 0.15 mm (0.0059 in) CAUTION: If reduction of outer diameter appears in a position other than d2, use it as d2 point.

Cylinder head bolt washer

Cylinder head side

SEM877A

3. a. b. c. d.

Tighten cylinder head bolts using the following procedure. Tighten all bolts to 39 N⋅m (4.0 kg-m, 29 ft-lb). Tighten all bolts to 78 N⋅m (8.0 kg-m, 58 ft-lb). Loosen all bolts completely. Tighten all bolts to 39 N⋅m (4.0 kg-m, 29 ft-lb).

SEM986C

e.

Method A degrees degrees

SEM043G

Method B

Method A: Turn all bolts 90 to 95 degrees clockwise with Tool or suitable angle wrench. Method B: If an angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 90 to 95 degrees clockwise. f. Turn all bolts another 90 to 95 degrees clockwise. g. Ensure that paint mark on each bolt faces the rear of the engine. (Method B only) Do not turn any bolt 180 to 190 degrees clockwise all at once.

degrees

degrees

Engine front Paint mark

SEM044G

EM-100

SR20DE

CYLINDER HEAD

Installation (Cont’d)

N·m (kg-m, ft-lb)

Tightening torque N⋅m (kg-m, ft-lb)

118 (12, 87)

Plastic zone

78 (8, 58) Elastic zone 39 (4, 29)

AEM113

Water inlet

Water outlet

a.

39 (4.0, 29)

b.

78 (8.0, 58)

c.

0 (0, 0)

d.

39 (4.0, 29)

e.

90 - 95 degrees (90 degrees preferred)

f.

90 - 95 degrees (90 degrees preferred)

4. 5. I I

Install Install Water Water

cylinder head outside bolts. the following water hoses: hose for cylinder block. hoses for heater.

6.

Install starter motor.

7.

Remove old liquid gasket from mating surface of LH camshaft end bracket. Also remove old liquid gasket from mating surface of cylinder head. Apply liquid gasket to mating surface of LH camshaft end bracket as shown in illustration. Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.

SEM037G

SEM036G

Apply liquid gasket to the shaded area.

I 8. I

LH camshaft end bracket BEM004

9. I I I

RH camshaft key

LH camshaft key

Install camshafts, camshaft brackets. Position camshaft. LH camshaft key at about 12 o’clock. RH camshaft key at about 10 o’clock. Apply new engine oil to bearing and cam surfaces of camshafts before installing them.

SEM045G

EM-101

CYLINDER HEAD

SR20DE

Installation (Cont’d)

I

Position camshaft brackets as shown in the illustration. Apply new engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.

I

Arrange bolts (Size and length). A: M6 x 53.8 mm (2.12 in) B: M6 x 37 mm (1.46 in) C: M8 x 35 mm (1.38 in)

I

Tightening procedure STEP 1: RH camshaft Tighten bolts 9 - 10 in that order then tighten bolts 1 - 8 in numerical order. : 2 N⋅m (0.2 kg-m, 17 in-lb) LH camshaft Tighten bolts 11 - 12 in that order then tighten bolts 1 - 10 in numerical order. : 2 N⋅m (0.2 kg-m, 17 in-lb) STEP 2: Tighten bolts in numerical order. : 6 N⋅m (0.6 kg-m, 52 in-lb) STEP 3: Tighten bolts in numerical order. Bolt type A B : 9.8 - 11.8 N⋅m (1.0 - 1.2 kg-m, 7.2 - 8.7 ft-lb) Bolt type C : 18 - 25 N⋅m (1.8 - 2.6 kg-m, 13 - 19 ft-lb)

End bracket

RH camshaft bracket

End bracket

Engine front No. 1 to 4 brackets No. 1 to 4 brackets

LH camshaft bracket SEM098DA

Engine front

Bolt type SEM046G

RH camshaft

Engine front

LH camshaft Tighten in numerical order.

SEM047G

Engine front

Bolt type SEM046G

Mating mark

Mating mark

Mating mark

.

Mating mark

.

RH camshaft sprocket

10. Install camshaft sprockets and timing chain on them. Line up mating marks on timing chain with mating marks on camshaft sprockets.

LH camshaft sprocket SEM048G

EM-102

CYLINDER HEAD

SR20DE Installation (Cont’d)

I

Lock camshafts as shown in figure and tighten to specified torque. : 137 - 157 N⋅m (14.0 - 16.0 kg-m, 101 - 116 ft-lb) Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.

SEM049G

11. Install distributor. I Make sure that position of camshaft is as shown in figure.

SEM050G Rotor head position (No. 1 cylinder at TDC)

I

Make sure that No. 1 piston is set at TDC and that distributor rotor is set at No. 1 cylinder spark position.

SEM033G

12. Install chain tensioner. Make sure the camshaft sprockets are tightened completely. Press cam stopper down and “press-in” sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow “A” points toward engine front.

SEM990C

SEM991C

EM-103

CYLINDER HEAD

SR20DE

Installation (Cont’d)

13. Install thermostat housing with water pipe. 16 - 20 (1.6 - 2.1, 12 - 15) 16 - 20 (1.6 - 2.1, 12 - 15)

6.3 - 8.3 (0.64 - 0.85, 56 - 73)

16 - 20 (1.6 - 2.1, 12 - 15)

6.3 - 8.3 (0.64 - 0.85, 56 - 73) 16 - 20 (1.6 - 2.1, 12 - 15)

N·m (kg-m, in-lb) N·m (kg-m, ft-lb)

SEM066G

14. Install intake manifold supports. Intake manifold supports

SEM030G

(0.39)

Engine front Unit: mm (in)

15. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head. 16. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations. I Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.

(0.39) 3 (0.12) BEM006

3 mm (0.12 in) dia.

SEM051G

EM-104

CYLINDER HEAD

SR20DE Installation (Cont’d)

Rocker cover

Engine front

Tighten in numerical order.

SEM052G

17. Install rocker cover and oil separator. I Be sure to install washers between bolts and rocker cover. I Tightening procedure STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order. STEP 2: Tighten bolts 1 - 13 in that order. : 8 - 10 N⋅m (0.8 - 1.0 kg-m, 69 - 87 in-lb) 18. Install the following parts: I Spark plugs and leads I Radiator Refit hoses and refill with coolant. Refer to MA-29, “Changing Engine Coolant”. I Front RH wheel I Engine undercovers 19. Connect the following: I Vacuum hoses I Fuel hoses I Wire harnesses and connectors I Air duct to intake manifold I Front exhaust tube

EM-105

SR20DE

ENGINE REMOVAL Components

Components SEC. 112 Rear engine slinger Front engine slinger

20.6 - 26.5 (2.1 - 2.7, 15 - 20) 20.6 - 26.5 (2.1 - 2.7, 15 - 20)

43 - 55 (4.9 - 5.6, 32 - 41)

43 - 55 (4.4 - 5.6, 32 - 41)

49 - 59 (5.0 - 6.0, 36 - 44)

43 - 55 (4.4 - 5.6, 32 - 41)

Front engine mounting Rear engine mounting

Mounting bracket

CVT models .

.

43 - 55 (4.4 - 5.6, 32 - 41)

49 - 59 (5.0 - 6.0, 36 - 44)

74 - 83 (7.5 - 8.5, 54 - 61) 43 - 55 (4.4 - 5.6, 32 - 41) .

64 - 74 (6.5 - 7.5, 47 - 54)

43 - 55 (4.4 - 5.6, 32 - 41)

43 - 55 (4.4 - 5.6, 32 - 41)

43 - 55 (4.4 - 5.6, 32 - 41)

64 - 74 (6.5 - 7.5, 47 - 54) 62 - 78 (6.3 - 8.0, 46 - 58)

55 - 65 (5.6 - 6.6, 41 - 48)

64 - 74 (6.5 - 7.5, 47 - 54) Front mounting bracket 49 - 59 (5.0 - 6.0, 36 - 44)

49 - 59 (5.0 - 6.0, 36 - 44)

Rear insulator Insulator

Center member

77 - 98 (7.9 - 100, 57 - 72) : N·m (kg-m, ft-lb)

NEM340

EM-106

ENGINE REMOVAL

SR20DE Components (Cont’d)

WARNING: I Position vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled; Otherwise, you may burn yourself and/or fire may break out in fuel line. I Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to “Releasing Fuel Pressure” in EC section. I Be sure to hoist engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach slingers and bolts described in PARTS CATALOG. CAUTION: I When lifting engine, be sure to clear surrounding parts. Use special care for accelerator cable, brake lines and brake master cylinder. I In hoisting the engine, always use engine slingers in a safe manner. I When removing drive shaft, be careful not to damage grease seal of transaxle.

Removal 1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove engine under cover and hood. Drain coolant from both cylinder block, and radiator. Drain engine oil. Remove vacuum hoses, fuel hoses, wires, harness and connectors. Remove exhaust tubes, ball joints and drive shafts. Remove radiator and fans. Remove drive belts. Remove alternator, compressor and power steering oil pump from engine. Set a suitable transmission jack under transaxle. Hoist engine with engine slinger.

10. Remove center member. Center member

Transmission jack SEM092D

EM-107

ENGINE REMOVAL

SR20DE

Removal (Cont’d)

11. Remove engine mounting bolts from both sides and then slowly lower transmission jack.

Front engine mounting

SEM597D

.

Rear engine mounting NEM224

12. Remove engine with transaxle as shown.

SEM195F

Installation 1. Install engine mounting bracket and fixing bolts. Be sure that insulators are correctly positioned on the brackets. 2. Carefully lower the engine onto engine mounting insulators.

Rubber seat

Insulator SEM312D

EM-108

SR20DE

CYLINDER BLOCK

Components

Components SEC. 110⋅120⋅150 16 - 21 (1.6 - 2.1, 12 - 15)

4 p

1 p

2 p

p 3

6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)

16 - 21 (1.6 - 2.1, 12 - 15) .

6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)

★

5 p

★ .

6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0) 6 p

Gasket 16 - 19 (1.6 - 1.9, 12 - 14)

6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.0)

24 p

pp p 23

22

21

83 - 93 (8.5 - 9.5, 61 - 69)

7 p

8 p 9 p

10 p

20 p

p 12 p 11

Snap ring

Refer to “Assembly”

13 p

Refer to “Assembly”

16 p

6.4 - 7.5 ü★ üü: Refer to LC section. (0.65 - 0.76, 56.6 - 66.0) ★★ : Refer to “Installation” in “OIL PAN”. 17 29 - 39 p (3.0 - 4.0, 22 - 29) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) : Apply liquid gasket. : Lubricate with new engine oil. üü

: Do not re-use

★★

14 p 15 p

★★ 19 p

Washer 6.4 - 7.5 (0.65 - 0.76, 56.6 - 66.4)

18 p

★★ 6.4 - 7.5 (0.65 - 0.76, 56.4 - 66.0)

NEM225

1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p

Rear oil seal retainer Cylinder block Water pump Power steering oil pump adjusting bar Front cover with oil pump Oil strainer Thrust bearing Crankshaft

9 p 10 p 11 p 12 p 13 p 14 p 15 p 16 p

Connecting rod bushing Piston rings Piston Piston pin Connecting rod Connecting rod bearing Aluminum oil pan Rear cover plate

EM-109

17 p 18 p 19 p 20 p 21 p 22 p 23 p 24 p

Drain plug Steel oil pan Baffle plate Main bearing cap Flywheel Pilot bushing Rear plate Main bearing

CYLINDER BLOCK

SR20DE

Components (Cont’d)

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

Disassembly

: N·m (kg-m, ft-lb)

PISTON AND CRANKSHAFT 1. 2. 25 - 34 (2.5 -3.5, 18 - 25) Spacer [5 mm (0.20 in) thickness]

3. 4.

25 - 34 (2.5 - 3.5, 18 - 25)

Place engine on a work stand. Remove cylinder head. Refer to “Removal” in “CYLINDER HEAD” (EM-87). Remove oil pan. Refer to “Removal” in “OIL PAN” (EM-70). Remove timing chain. Refer to “Removal” in “TIMING CHAIN” (EM-76).

SEM141FA

5. I

Piston heater

Oil

6.

Remove pistons with connecting rods. When disassembling piston and connecting rod, remove snap ring first. Then heat piston to 60 to 70°C (140 to 158°F), or use piston pin press stand at room temperature. Remove rear oil seal retainer.

SEM877B

7. Front

I

4 p

8 p

10 p

6 p

2 p

3 p

7 p

9 p

5 p

1 p

I

Remove bearing caps and crankshaft in numerical order as shown in the figure. Before removing bearing cap, measure crankshaft end play. Bolts should be loosened in two or three steps.

NEM150

Inspection PISTON AND PISTON PIN CLEARANCE 1.

Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: 21.993 - 22.005 mm (0.8659 - 0.8663 in)

AEM023

EM-110

CYLINDER BLOCK

SR20DE Inspection (Cont’d)

2.

3.

Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: 21.989 - 22.001 mm (0.8657 - 0.8662 in) Calculate piston pin clearance. dp − Dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in) If it exceeds the above value, replace piston assembly with pin.

Micrometer AEM024

PISTON RING SIDE CLEARANCE NG

Side clearance: Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in) Max. limit of side clearance: 0.2 mm (0.008 in) If out of specification, replace piston and/or piston ring assembly.

Feeler gauge OK

Feeler gauge Ring

SEM024AA

PISTON RING END GAP

SEM822B Bend

Feeler gauge

End gap: Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in) 2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in) Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in) Max. limit of ring gap: 1.0 mm (0.039 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use over-sized piston and piston rings. Refer to SDS (EM-193). I When replacing the piston, inspect cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

SEM038F

Torsion

Feeler gauge

Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly.

SEM003F

EM-111

CYLINDER BLOCK

SR20DE

Inspection (Cont’d)

CYLINDER BLOCK DISTORTION AND WEAR

Straightedge

1.

2. Feeler gauge

Clean upper face of cylinder block and measure the distortion. Standard: Less than 0.03 mm (0.0012 in) Limit: 0.10 mm (0.0039 in) If out of specification, resurface it. The resurfacing limit is determined by cylinder head resurfacing in engine.

SEM123C

211.25 - 211.35 mm (8.3169 - 8.3208 in)

Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 211.25 - 211.35 mm (8.3169 - 8.3208 in) 3. If necessary, replace cylinder block. SEM008D

PISTON-TO-BORE CLEARANCE

100 (3.94)

60 (2.36) 10 (0.39)

1.

SEM363E

Cylinder bore grade number

2. I

.

Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Standard inner diameter: 86.000 - 86.030 mm (3.3858 - 3.3870 in) Wear limit: 0.20 mm (0.0079 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (X − Y) standard: Less than 0.015 mm (0.0006 in) Taper (A − B and A − C) standard: Less than 0.010 mm (0.0004 in) Check for scratches and seizure. If seizure is found, hone it. When replacing both cylinder block and piston with new ones, select piston making sure of grade numbers. Piston grade number should be the same as the grade number punched on cylinder block upper surface.

SEM011D

3.

SEM012D

Measure piston skirt diameter. Piston diameter “A”: Refer to SDS (EM-193). Measuring point “a” (Distance from the bottom): 13.1 mm (0.516 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance “B”: 0.010 - 0.030 mm (0.0004 - 0.0012 in) 5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS (EM193).

EM-112

CYLINDER BLOCK

SR20DE Inspection (Cont’d)

6.

Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”. Rebored size calculation: D= A+B−C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque. I Otherwise, cylinder bores may be distorted in final assembly. 8. Cut cylinder bores. I When any cylinder needs boring, all other cylinders must also be bored. I Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. I Measurement should be done after cylinder bore cools down.

CRANKSHAFT 1. 2.

Taper: Out-of-round: SEM316A

3.

Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X − Y) standard: Main journal: Less than 0.005 mm (0.0002 in) Pin journal: Less than 0.0025 mm (0.0001 in) Taper (A − B) standard: Main journal: Less than 0.005 mm (0.0002 in) Pin journal: Less than 0.0025 mm (0.0001 in)

Measure crankshaft runout. Runout (Total indicator reading) limit: Less than 0.05 mm (0.0020 in)

.

SEM434

EM-113

CYLINDER BLOCK

SR20DE

Inspection (Cont’d)

BEARING CLEARANCE I

Use either of the following two methods, however, method “A” gives more reliable results and is preferred.

Method A (Using bore gauge & micrometer) Main bearing 1.

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

SEM685D

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

SEM100D

4. 5.

6. 7.

Measure outer diameter “Dm” of each crankshaft main journal. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in) Limit: 0.050 mm (0.0020 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing.

AEM026

a.

b.

When grinding crankshaft journal, confirm that “L” dimension in fillet roll is more than the specified limit. “L”: 0.1 mm (0.004 in) Refer to SDS for grinding crankshaft and available service parts.

SEM964

8. Main journal grade number No. 5

a.

No. 1

If crankshaft is reused, measure main bearing clearances and select thickness of main bearings. If crankshaft is replaced with a new one, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.

Engine front SEM313D

EM-114

SR20DE

CYLINDER BLOCK

Inspection (Cont’d) Type I

b.

Main journal grade number No. 5

c.

Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Roman numerals. Select main bearing with suitable thickness according to the following table.

No. 1 No. 4

Crankshaft front view Type II

SEM013D

How to select main bearings (Identification mark and color) Crankshaft main journal grade number

Main journal grade number No. 1

Cylinder block main journal grade number 0

1

2

3

0

0 (A, Black)

1 (B, Red)

2 (C, Green)

3 (D, Yellow)

1

1 (B, Red)

2 (C, Green)

3 (D, Yellow)

4 (E, Blue)

2

2 (C, Green)

3 (D, Yellow)

4 (E, Blue)

5 (F, Pink)

3

3 (D, Yellow)

4 (E, Blue)

5 (F, Pink)

6 (G, White)

No. 5 journal

Crankshaft front view

For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (D, Yellow)

SEM203D

Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter “C” of each bearing.

Inside micrometer

AEM027

4. 5.

6. 7.

Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to step 7 of “BEARING CLEARANCE − Main bearing” (EM-114).

AEM028

EM-115

SR20DE

CYLINDER BLOCK Inspection (Cont’d) Type I

8.

If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. Connecting rod bearing grade number: These numbers are punched in either Arabic or Roman numerals.

Main journal grade number No. 5

No. 1 No. 4

Crankshaft front view

Crank pin grade number

Connecting rod bearing grade number

0

0

1

1

2

2

SEM013D

Identification color: Grade 0; Black or Yellow Grade 1; Brown or Red Grade 2; Green or Blue

Type II No. 3 No. 2

No. 4 cylinder Grade 0 Grade 1

No. 1

Grade 2 Pin journal grade number

Crankshaft rear view

SEM204D

Method B (Using plastigage) CAUTION: I Do not turn crankshaft or connecting rod while plastigage is being inserted. I When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance. EM142

CONNECTING ROD BUSHING CLEARANCE (Small end) 1.

Measure inner diameter “C” of bushing. Refer to SDS EM-193 - “CONNECTING ROD”.

2. 3.

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

AEM029

Micrometer AEM030

EM-116

SR20DE

CYLINDER BLOCK

Inspection (Cont’d)

REPLACEMENT OF CONNECTING ROD BUSHING (Small end) 1.

Align. SEM062A

Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing. This is to ensure the clearance between connecting rod bushing and piston pin is the specified value. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (CVT) 1.

Remove pilot bushing or pilot converter using Tool or suitable tool.

2.

Install pilot bushing or pilot converter as shown.

SEM916AB

Crankshaft side

M/T

CVT SEM163B

FLYWHEEL/DRIVE PLATE RUNOUT Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (CVT model) Less than 0.20 mm (0.0079 in) CAUTION: Do not allow any magnetic materials to contact the ring gear teeth. .

SEM901E

Assembly PISTON 1.

Install new snap ring on one side of piston pin hole.

SEM166B

EM-117

CYLINDER BLOCK

SR20DE

Assembly (Cont’d)

2. I I I

Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.

SEM946C

Punchmark side up (if mark is present.)

3. Set piston rings as shown. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, those without punchmarks can be mounted with either side up.

SEM965E

Oil ring expander

● Top ring ● Oil ring

upper rail

Engine front

2nd ring

Oil ring lower rail NEM336

CRANKSHAFT 1. I I

Set main bearings in their proper positions on cylinder block and main bearing cap. Confirm that correct main bearings are used. Refer to “Inspection” of this section. Apply new engine oil to bearing surfaces.

SEM685D

EM-118

CYLINDER BLOCK

SR20DE Assembly (Cont’d)

2. Front

7 p

8 p

3 p

1 p

4 p

2 p

5 p

6 p

9 p

10 p

NEM151

I I I a. b. I

KV10112100

I

Install crankshaft and main bearing caps and tighten bolts to the specified torque and in numerical order as shown in the figure. Apply new engine oil to thread of bearing cap bolts. Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap. Tightening procedure Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28 ft-lb). Turn all bolts 30 to 35 degrees clockwise with Tool or suitable angle wrench. If an angle wrench is not available, mark all bearing cap bolts on the side facing engine rear. Then, turn each bolt specified degrees clockwise. Confirm angle of degrees with a graduator, not by eye-measurement. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

NEM152

3.

Measure crankshaft end play. Crankshaft end play: Standard 0.10 - 0.26 mm (0.0039 - 0.0102 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace thrust bearings with new ones.

4.

Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to “Inspection”. Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bolt threads and bearing surfaces.

Feeler gauge

NEM153 Align oil hole.

I I I

SEM159B

5. a. I I I

Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall by connecting rod. Arrange so that front mark on piston head faces toward front of engine. Apply new engine oil to piston rings and sliding surface of piston.

EM03470000 or suitable tool SEM554EA

EM-119

CYLINDER BLOCK

SR20DE

Assembly (Cont’d)

b.

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

6.

Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.50 mm (0.0197 in) If beyond the limit, replace connecting rod and/or crankshaft.

7. a.

Install rear oil seal retainer. Before installing rear oil seal retainer, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.

Engine front

Connecting rod cap nut

NEM154

Feeler gauge

NEM153

●

SEM218D

b. Liquid gasket

●

Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. Use Genuine Liquid Gasket or equivalent.

2.0 - 3.0 mm (0.079 0.118 in)

SEM219D

EM-120

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Camshaft bearing noise

CD20T

Tappet noise Belt tensioner noise

Valve mechanism Timing belt

Belt tensioner noise

Water pump

Rotation mechanism Piston pin noise Drive belt

Piston slap noise

Main bearing noise

Connecting rod bearing noise

Drive belt noise (stick/slipping) Drive belt noise (Slipping) NEM333

EM-121

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

CD20T

NVH Troubleshooting Chart — Engine Noise

NVH Troubleshooting Chart — Engine Noise Use the chart below to help you find the cause of the problem. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Type of noise

When starting

When idling

When racing

While driving

Source of noise

Check item

Reference page

Ticking or clicking

C

A

—

A

B

—

Tappet noise

Valve clearance

—

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-147

Slap or knock

—

A

—

B

B

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-168, 171

EM-168, 169, 172, 174

Slap or rap

A

—

—

B

B

A

Piston slap noise

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

Knock

A

B

C

B

B

B

Connecting rod bearing noise

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

EM-170, 171

Knock

A

B

—

A

B

C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-169, 172

C

A

—

A

A

—

Timing belt noise (too tight)

Loose timing belt Belt contacting case

EM-135

Whine or Camshaft and injection hissing pump Timing belt Clatter cover

Squeaking or fizzing Front of engine

Before After warm-up warm-up

A

B

—

C

A

—

Timing belt noise (too loose)

A

B

—

B

—

C

Other drive belts (Sticking or slipping)

Drive belts deflection

Idler pulley bearing operation

Water pump operation

Creaking

A

B

A

B

A

B

Other drive belts (Slipping)

Squall Creak

A

B

—

B

A

B

Water pump noise

A: Closely related B: Related C: Sometimes related —: Not related *1: MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) *2: LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)

EM-122

*1

*2

CD20T

OUTER COMPONENT PARTS Right side SEC. 130⋅135⋅185⋅186⋅210⋅213⋅233 17 - 21 (1.7 - 2.1, 12 - 15) 2 - 4 (0.2 - 0.4, 18 - 35)

3 - 5 (0.3 0.5, 26 - 43)

16 - 21 (1.6 - 2.1, 12 - 15) 49 - 59 (5.0 - 6.0, 36 - 43)

49 - 59 (5.0 - 6.0, 36 - 43)

16 - 21 (1.6 - 2.1, 12 - 15) 16 - 21 (1.6 - 2.1, 12 - 15)

31 - 42 (3.2 - 4.3, 23 - 31)

22 - 25 (2.2 - 2.5, 16 - 18) 54 - 64 (5.5 - 6.5, 40 - 47) 16 - 21 (1.6 - 2.1, 12 - 15)

üü

: Apply liquid gasket : N·m (kg-m, in-lb)

üü

: N·m (kg-m, ft-lb) : Do not re-use NEM240

1 p 2 p 3 p 4 p 5 p 6 p 7 p

Starter motor Injection pump Injection tube Thermostat housing Injection nozzle Spill hose Water outlet

8 p 9 p 10 p 11 p 12 p 13 p 14 p

Belt cover Timing belt Injection pump sprocket Rear camshaft sprocket Tensioner Vacuum pump Rear back cover

EM-123

15 p 16 p 17 p 18 p 19 p

Oil cooler Gasket Bracket Power steering oil pump adjusting bar Gasket

CD20T

OUTER COMPONENT PARTS Left side SEC. 120⋅135⋅140⋅144⋅210⋅230

18 - 22 (1.8 - 2.2, 13 - 16) 3.8 - 4.5 (0.39 - 0.46, 33.6 - 39.8)

3 - 5 (0.3 - 0.5, 27 - 44)

37 - 50 (3.8 - 5.1, 27 - 37)

6.3 - 8.3 (0.64 - 0.85, 55.8- 73.5)

p

11 p

8

16 p

.

9 p

1 p

21 - 26 (2.1 - 2.7, 15 - 20)

10 p

8 p 12 p

6.4 - 8.4 (0.65 - 0.86, 56.6 - 74.3)

13 p

18 - 22 (1.8 - 2.2, 13 - 16)

2 p

8 p 3 p

p

8 p 7 p

3-5 (0.3 - 0.5, 26 - 44)

4 p

21 - 26 (2.1 - 2.7, 15 - 20)

14

39 - 49 (4.0 - 5.0, 29 - 36)

18 - 22 (1.8 - 2.2, 13 - 16) .

142 - 152 (14.5 - 15.5, 105 - 112)

6 p

18 - 22 (1.8 - 2.2, 13 - 16)

17 p

20 - 31 (2.0 - 3.2, 14 - 23)

15 p

4-5 (0.4 - 0.5, 35 - 44)

70 - 89 (7.1 - 9.1, 51 - 66)

16 - 21 (1.6 - 2.1, 12 - 15)

5 p

üü

: Apply liquid gasket : N·m (kg-m, in-lb)

16 - 21 (1.6 - 2.1, 12 - 15)

üü

: N·m (kg-m, ft-lb) : Do not re-use

41 - 52 (4.2 - 5.3, 30 - 38)

1 p 2 p 3 p 4 p 5 p 6 p

Belt cover upper Water pump pulley Belt cover lower Crankshaft pulley Alternator Alternator bracket

7 p 8 p 9 p 10 p

Exhaust manifold with turbocharger assembly Gasket Intake manifold EGR passage (To install, face EGR gas discharge port upward)

EM-124

11 p 12 p 13 p 14 p 15 p 16 p 17 p

NEM197

EGR valve Air inlet Air inlet hose EGR tube Exhaust manifold cover Blow-by gas control valve Turbocharger oil return hose

CD20T

OUTER COMPONENT PARTS Left side SEC. 140⋅144

2 p

20 - 31 (2.0 - 3.2, 14 - 23) 20 - 31 (2.0 - 3.2, 14 - 23)

12 p

13 p

3 p

4 p

20 - 31 (2.0 - 3.2, 14 - 23)

5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.5)

1 p

6 p

22 - 29 (2.2 - 3.0, 16 - 22) 7 p

5 p

5.1 - 6.5 (0.52 - 0.66, 45.1 - 57.5)

8 p 3 p

p

14 p

3

9 p

13 - 19 (1.3 - 1.9, 9 - 14) .

10 p

7.2 - 9.6 (0.73 - 0.98, 63.7 - 85.0)

10 - 13 (1.0 - 1.3, 7.2 - 9.4)

20 - 31 (2.0 - 3.2, 14 - 23)

15 p

üü

: Apply liquid gasket : N·m (kg-m, in-lb)

22 - 29 (2.2 - 3.0, 16 - 22) üü

: N·m (kg-m, ft-lb) : Do not re-use

15 p

6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)

11 p

NEM375

1 p 2 p 3 p 4 p 5 p

Turbocharger assembly Exhaust manifold Gasket Air inlet hose Air hose

6 p 7 p 8 p 9 p 10 p

Lock plate Exhaust outlet Exhaust outlet cover Turbocharger oil return pipe Turbocharger oil return hose

EM-125

11 p 12 p 13 p 14 p 15 p

Insulator Turbocharger oil feed tube Turbocharger water feed tube Turbocharger water return tube Bracket

COMPRESSION PRESSURE

CD20T

1. 2.

Warm up engine sufficiently. Remove spill hoses.

3.

Disconnect injection tubes on nozzle side and loosen injection tubes on pump side. Release clamps on injection tubes. Use two wrenches to prevent delivery holder on pump side from loosening.

NEM241

I

SEM501D

4.

Remove all injection nozzles using S.S.T. KV119E0030.

5.

Turn ignition switch off and disconnect harness connector (black colored) at injection pump.

6.

Fit compression gauge to cylinder head.

NEM242

NEM243

SEM505D

EM-126

CD20T

COMPRESSION PRESSURE 7.

8.

Crank engine and read compression gauge indication. Cranking speed: 200 rpm Compression pressure: kPa (bar, kg/cm2, psi) Standard 3,138 (31.4, 32, 455) Limit 2,452 (24.5, 25, 356) Limit of difference between cylinders 490 (4.9, 5, 71) If the pressure appears low, pour about 3 m (0.11 Imp fl oz) of engine oil through nozzle holes and repeat test. For indications of test, refer to the following table.

Gauge indication during tests

Trouble diagnosis

● Piston rings are worn or damaged.

● If two adjacent cylinders are low, gasket is damaged. ● Valve is sticking. ● Valve seat or valve contact surface is incorrect.

EM-127

COMPRESSION PRESSURE

Nozzle side

CD20T

9. Replace nozzle gaskets and re-install injection nozzles. New nozzle gaskets must be installed in the direction shown. Nozzle to cylinder head: : 54 - 64 N·m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)

Combustion chamber side NEM244

10. Install injection tubes using two wrenches as shown. Injection tubes: : 22 - 25 N·m (2.2 - 2.5 kg-m, 16 - 18 ft-lb)

SEM501D

NEM242

11. Install spill hoses. 12. Initialize the ECM. Refer to EC-section (“HOW TO ERASE DTC”).

NEM241

EM-128

OIL PAN

CD20T Removal

Removal 1. 2. 1) I I

Drain oil. Remove oil pan using tool as illustrated. Insert Tool between oil pan and cylinder block. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating surfaces will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.

SEM230D

2)

Slide Tool by tapping it with a hammer, and remove oil pan.

SEM231D

Installation 1.

Scraper

I

Before installing oil pan, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.

SEM350B

I Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. Use Genuine Liquid Gasket or equivalent.

SLC906

2.

Apply liquid gasket to inner sealing surface as shown at left.

SEM909B

EM-129

OIL PAN

CD20T

Installation (Cont’d)

3.

Apply liquid gasket to oil pan front oil seal and rear oil seal.

4.

Apply a continuous bead of liquid gasket to mating surface of oil pan. Attaching should be done within 5 minutes after coating.

SEM894BA

Tube presser

I

SEM351B

5.

Install oil pan and tighten bolts in the order shown in the figure. Wait at least 30 minutes before refilling engine oil. Oil pan bolts: : 6.3 - 8.3 N·m (0.64 - 0.85 kg-m, 55.8 - 73.5 in-lb) Engine front

SEM369D

EM-130

CD20T

TIMING BELT

Camshaft Timing Belt

Camshaft Timing Belt CAUTION: a. Do not bend or twist timing belt. b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike piston heads. c. Ensure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free from oil and water. SEC. 112⋅120⋅130⋅135 87 - 107 (8.9 - 10.9, 64 - 79)

5.3 - 7.3 (0.54 - 0.74, 46.9 - 64.6)

3-5 (0.3 - 0.5, 27 - 44)

32 - 40 (3.3 - 4.1, 24 - 30)

32 - 40 (3.3 - 4.1, 24 - 30) 43 - 58 (4.4 - 5.9, 32 - 43)

142 - 152 (14.5 - 15.5, 105 - 112) : üDo not re-use Lubricate with new engine oil. N·m (kg-m, in-lb) N·m (kg-m, ft-lb)

6.4 - 8.4 (0.65 - 0.86, 56.6 - 74.3)

3 - 5 (0.3 - 0.5, 27 - 44)

Locking sealant SEM368FA

1 p 2 p 3 p 4 p

Front camshaft sprocket Idler Belt tensioner Crankshaft sprocket

5 p 6 p 7 p

Belt cover lower Belt cover center (Engine mounting bracket) Timing belt

8 p 9 p 10 p

Belt cover upper Gasket Front camshaft sprocket plate

REMOVAL 1. 2. 3.

Drain engine coolant from radiator. Remove upper radiator hose and upper belt cover. Remove water pump pulley.

Upper radiator hose SEM047F

EM-131

TIMING BELT

CD20T

Camshaft Timing Belt (Cont’d)

4.

Set No. 1 cylinder at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)

5.

Remove starter motor, and install ring gear stopper using mounting bolt holes. Remove crank pulley bolt. Remove crank pulley using puller. Be sure to securely attach puller jaws. Attach jaws only to the rear side of pulley. Remove lower belt cover.

SEM369F

6. 7.

8.

SEM681D

9. Remove timing belt. (1) Loosen tensioner pulley bolt, turn tensioner pulley counterclockwise then tighten bolt. (2) Remove camshaft sprocket plate.

Tighten Loosen

SEM520D

(3) Remove idler pulley.

SEM515D

(4) Remove timing belt with crankshaft sprocket. CAUTION: Do not allow any magnetic materials to contact crankshaft sprocket. (5) Remove tensioner pulley and return spring.

SMA398A

EM-132

CD20T

TIMING BELT

Inspection

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

Problem

Cause I Camshaft jamming I Damaged camshaft/crankshaft oil seal

Tooth is broken/tooth root is cracked.

SEM394A

I Tensioner jamming I Overheated engine I Interference with belt cover

Back surface is cracked/ worn.

SEM395A

I Improper installation of belt I Malfunctioning crankshaft pulley plate/timing belt plate

Side surface is worn.

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

SEM396A

I I I I

Teeth are worn.

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

Rotating direction

I Canvas on tooth face is worn down. I Canvas on tooth is fluffy, rubber layer is worn down and faded white, or weft is worn down and SEM397A invisible. I Poor oil sealing of each oil seal I Coolant leakage at water pump I Poor belt cover sealing

Oil, coolant or water is stuck to belt.

EM-133

TIMING BELT

CD20T

Inspection (Cont’d)

Belt tensioner, tensioner spring and idler 1. 2.

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

SEM558

Crankshaft sprocket and front camshaft sprocket Check teeth for abnormal signs.

SEM516D

Installation 1.

Confirm that No. 1 piston is set at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)

SEM517D

2. Install tensioner and return spring. Temporarily tighten bolts so that tensioner is set at the fully outside position. 3. Install idler and tighten bolt to the specified torque.

SEM518D Mark

Align

4. a.

43 cogs

b. 5.

Install timing belt with crankshaft sprocket. Align white lines on timing belt with punchmarks on camshaft sprocket and crankshaft sprocket. Point arrow on timing belt toward belt cover. Install camshaft sprocket plate and secure screws with Loctite.

Align

SEM519DA

EM-134

CD20T

TIMING BELT

Installation (Cont’d)

6. 1) 2) Tighten

3)

Loosen

SEM520D

Adjust timing belt tension. Loosen tensioner lock bolt to apply tension to timing belt. Rotate crankshaft clockwise two turns to apply the specified tension to timing belt. Tighten tensioner lock bolt while holding tensioner pulley with hexagon wrench. Belt tension: 147.1 ± 24.5 N (15 ± 2.5 kg, 33.1 ± 5.5 lb)

Injection Pump Timing Belt

SEC. 130⋅135 31 - 37 (3.2 - 3.8, 23 - 27)

3-5 (0.3 - 0.5, 27 - 44)

17 - 21 (1.7 - 2.1, 12 - 15)

87 - 107 (8.9 - 10.9, 64 - 79)

59 - 69 (6.0 - 7.0, 43 - 51) Engine front

N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Lubricate with new engine oil 16 - 21 (1.6 - 2.1, 12 - 15)

SEM349F

1 p 2 p 3 p

Timing belt Tensioner spring Tensioner

4 p 5 p 6 p

Rear camshaft sprocket Injection pump sprocket Vacuum pump

7 p 8 p

Timing belt cover Grommet

REMOVAL 1. 2. 3. 4. 5.

Remove battery from engine room. Remove air cleaner case, air duct and resonator. Disconnect all piping connections from vacuum pump. Remove water pipe mounting bolt under injection pump timing belt cover, then remove water pipe. Remove timing belt cover.

EM-135

TIMING BELT

CD20T

Injection Pump Timing Belt (Cont’d)

6.

Set No. 1 cylinder at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.)

I

Make sure that alignment marks of rear camshaft sprocket and injection pump sprocket are positioned as shown.

7.

Apply alignment marks on the back of timing belt according to rear camshaft sprocket and injection pump sprocket alignment marks. Also apply a front mark on the back of timing belt.

SEM369F

Alignment mark

Alignment mark SEM350F Front mark Alignment mark

Alignment mark SEM351F

8.

Loosen tensioner mounting nut. Using a screwdriver, turn tensioner in direction of arrow to release belt tension. 9. Remove vacuum pump. 10. Remove timing belt.

Tensioner

.

SEM352F

INSTALLATION 1. I

Confirm that No. 1 piston is set at TDC on its compression stroke. (TDC is indicated by crankshaft pulley notch without painted mark.) If injection pump sprocket was removed, confirm that it is reinstalled as illustrated. Identification of alignment: Use mark “p B ”

SEM370F

EM-136

TIMING BELT

CD20T Injection Pump Timing Belt (Cont’d)

Front mark Alignment mark

2. 1) 2) 3)

Install timing belt. Set timing belt with the front mark facing front of engine. Install vacuum pump. Position timing belt matching the alignment marks with rear camshaft sprocket and injection pump sprocket alignment marks.

3. 1) I

Adjust belt tension. Loosen tensioner lock nut to apply tension to timing belt. Make sure that all sprocket and timing belt alignment marks are positioned as shown.

Alignment mark SEM351F

Alignment mark

Alignment mark SEM350F

2) Rotate crankshaft clockwise by two revolutions. Do not turn crankshaft by camshaft sprockets 3) Tighten tensioner lock nut while holding tensioner with a screwdriver. Belt tension: 98±49 N (10±5 kg, 22±11 lb) 4. Install timing belt cover. 5. Install remaining parts in the reverse order of removal. .

SEM353F

EM-137

OIL SEAL REPLACEMENT

CD20T

VALVE OIL SEAL 1. 2. 3. 4.

Remove both timing belts. Remove camshaft sprockets and back covers. Remove camshaft brackets by loosening bracket nuts from center to outside in two or three stages. Remove camshaft oil seals and camshaft.

SEM888

5. Remove valve lifters and mark order No. on each lifter. 6. Replace valve oil seal according to the following procedure. When replacing valve oil seal, set the corresponding piston at TDC. Failure to do so causes the valve to drop into the cylinder. 1) Set No. 1 cylinder at TDC. 2) Remove valve springs and valve oil seals for No. 1 and No. 4 cylinders. Valve spring seats should not be removed.

KV10107902

NEM200

12.2 ± 0.3 mm (0.480 ± 0.012 in)

3)

4) 5) 6) 7)

Install new valve oil seals for No. 1 and No. 4 cylinders as illustrated. Reinstall valve springs. (Narrow pitch side toward cylinder head) Install valve spring retainers on intake valves and valve rotators on exhaust valves, and remount valve assembly. Set No. 2 cylinder at TDC. Replace valve oil seals for No. 2 and No. 3 cylinders according to steps 2) and 3). Install valve lifters in original positions.

NEM201

CAMSHAFT AND CRANKSHAFT OIL SEAL INSTALLING DIRECTION AND MANNER I I

Engine outside

Engine inside

Oil seal lip

I

When installing camshaft and crankshaft oil seals, be careful to install them correctly, as shown in the figure. Apply engine oil to oil seal lip, outer face, camshaft and bracket. Wipe off excess oil after installing oil seal.

Dust seal lip

SEM715A

CAMSHAFT OIL SEALS 1. 2.

Tape

Remove timing belts, sprockets and back covers. Pull out oil seal with a suitable tool.

.

SEM887

EM-138

OIL SEAL REPLACEMENT

CD20T

3. Install new oil seals with a suitable tool. Confirm turning direction of both oil seals and camshaft.

Rear

Front

SEM240D

CRANKSHAFT FRONT OIL SEAL 1. 2.

Remove valve timing belt and crankshaft sprocket. Remove oil seal with a suitable tool.

3.

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

SEM889

SEM241D

CRANKSHAFT REAR OIL SEAL 1. 2. 3.

Remove transaxle assembly. (Refer to “REMOVAL AND INSTALLATION” in MT section.) Remove flywheel. Remove rear oil seal with a suitable tool.

SEM891

1.

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

SEM242D

EM-139

CD20T

CYLINDER HEAD Components

Components

SEM356F

1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p

Camshaft Front oil seal Collar Grommet Front back cover Front camshaft sprocket plate Front camshaft sprocket Spring

9 p 10 p 11 p 12 p 13 p 14 p 15 p

Selective cylinder head gasket Valve Spring seat Valve spring Valve oil seal Spring retainer (INT)/Valve rotator (EXH) Valve cotter

EM-140

16 p 17 p 18 p 19 p 20 p 21 p 22 p 23 p

Valve lifter with shim Rear back cover Rear camshaft sprocket Grommet Collar Rocker cover gasket Cam bracket Rear oil seal

CYLINDER HEAD

CD20T Removal

Removal 1. 2. 3. 4. 5.

Drain plug (cylinder block)

SEM373D

Drain coolant and disconnect front exhaust pipe from manifold. Remove water hoses, air duct and intake manifold. Remove heat shield and exhaust manifold. Remove rocker cover and injection tubes. Remove both timing belts. Set No. 1 cylinder at TDC on its compression stroke. Refer to “TIMING BELT” (EM-134). After timing belts have been removed, do not rotate crankshaft and/or camshaft separately as valves will hit piston heads. 6.

Remove cylinder head bolts in numerical order as shown in the figure.

SEM682D

Disassembly 1.

SEM864

Remove front camshaft sprocket plate, front and rear sprockets using special service tool or a suitable tool, and front back cover. 2. Remove camshaft brackets in order from outside to inside. I Loosen camshaft bracket nuts in two or three stages. 3. Remove camshaft and oil seals. 4. Remove valve lifters. For valve lifter I Attach tags to valve lifters for identification. 5. I

Remove valve component parts using special service tool or a suitable tool. Keep each valve and its components together and mark them so they can be reassembled in their original positions.

6.

Remove valve oil seals using special tool.

SEM716B

SEM745BA

EM-141

CYLINDER HEAD

CD20T

Inspection

Inspection CYLINDER HEAD DISTORTION 1. 2.

Warpage of surface: Less than 0.1 mm (0.004 in)

SEM595A

Visually check for cracks and deformation. Check cylinder head for distortion. Head surface flatness: Less than 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface cylinder head. Resurfacing limit: The resurfacing limit of the cylinder head is related to the amount of resurfacing of the cylinder block. When: “A” is the amount of resurfacing needed for the cylinder head and “B” is the amount of resurfacing needed for the cylinder block, the maximum limit is determined by A + B = 0.1 mm (0.004 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, the cylinder head must be replaced. Nominal height of cylinder head: 137.9 - 138.1 mm (5.429 - 5.437 in)

VALVE GUIDE CLEARANCE 1.

Measure deflection across the cylinder head as illustrated. Valve deflection limit (dial gauge reading): 0.1 mm (0.004 in)

2. a)

If exceeding the limit, check valve-to-guide clearance. Measure valve stem diameter and valve guide inner diameter as illustrated. Check that clearance is within the specification. Valve stem to valve guide clearance limit: 0.1 mm (0.004 in) If exceeding the limit, replace valve or valve guide.

SEM870 Micrometer

b)

c) Top Center Bottom Valve guide Valve

SEM244D

VALVE GUIDE REPLACEMENT 1. 2.

Heat cylinder head in oil to 150 to 160°C (302 to 320°F). Drive out valve guide using a press or hammer and a suitable tool.

SEM871

EM-142

CD20T

CYLINDER HEAD

Inspection (Cont’d)

.

3.

Ream cylinder head valve guide bore. Reaming bore (service part): 11.185 - 11.196 mm (0.4404 - 0.4408 in)

4.

Heat cylinder head to 150 to 160°C (302 to 320°F) and press service valve guide onto cylinder head. Ream valve guide. Final size: 7.000 - 7.015 mm (0.2756 - 0.2762 in)

SEM245D

10.3 mm (0.406 in)

5.

SEM246DA

VALVE SEATS 1.

Check valve and valve seat for contact. Coat the valve face with prussian red lead. If contact is wrong, correct valve seat. If the valve red lead appears 360° around face, the valve stem and face are concentric. If not, repair or replace valve.

SEM722BA

2.

Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. Correct valve seat surface. When repairing valve seat, check valve and valve guide for wear beforehand. If worn, replace them. Then correct valve seat.

VALVE SEAT REPLACEMENT 1. Recess diameter

SEM795A

Bore out old seat until it collapses. Set machine depth stop so that boring cannot contact bottom face of seat recess in cylinder head. 2. Ream the cylinder head recess. Reaming bore for service valve seat [Oversize 0.5 mm (0.020 in)]: Intake 41.432 - 41.454 mm (1.6312 - 1.6320 in) Exhaust 35.432 - 35.454 mm (1.3950 - 1.3958 in) Use the valve guide center for reaming to ensure valve seat will have the correct fit.

EM-143

CYLINDER HEAD

CD20T

Inspection (Cont’d)

3.

Heat cylinder head to a temperature of 150 to 160°C (302 to 320°F) and press fit seat until it seats on the bottom. 4. Install valve seats. When replacing valve seat, valve should be replaced as well.

5.

Cut or grind valve seat using a suitable tool at the specified dimensions as shown in SDS (EM-198). The cutting should be done with both hands to obtain a uniform and concentric finish.

SEM876

6.

Apply a small amount of fine grinding compound to the valve’s contacting face and put the valve into its guide. Lap valve against its seat until proper valve seating is obtained.

7.

Check valve seating condition.

SEM877

W: Refer to SDS.

SEM635AA

VALVE DIMENSIONS

T (Margin thickness)

1. 2.

Check dimensions of each valve. For dimensions, refer to SDS (EM-197). Correct or replace any valve that is faulty.

SEM188A

EM-144

CYLINDER HEAD

CD20T Inspection (Cont’d)

3.

Valve face or valve stem end surface should be refaced by using a valve grinder. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.5 mm (0.020 in) or less.

EM111

VALVE SPRING SQUARENESS

SEM333

Check valve spring for squareness using a steel square and flat surface plate. If spring is out of square “S” more than specified limit, replace with new one. Out-of-square: Outer Less than 1.8 mm (0.071 in) — Intake — Less than 2.2 mm (0.087 in) — Exhaust — Inner Less than 1.6 mm (0.063 in) — Intake — Less than 1.8 mm (0.071 in) — Exhaust —

VALVE SPRING PRESSURE LOAD Measure the free length and the tension of each spring. If the measured value exceeds the specified limit, replace spring. Refer to SDS (EM-197).

EM113

VALVE LIFTER 1.

Check contact and sliding surfaces for wear or scratches.

SEM723B

EM-145

CYLINDER HEAD

CD20T

Inspection (Cont’d)

2.

Check diameter of valve lifters. Outer diameter: 34.959 - 34.975 mm (1.3763 - 1.3770 in)

3.

Check valve lifter guide bore. Bore diameter 34.998 - 35.018 mm (1.3779 - 1.3787 in) Standard clearance 0.023 - 0.059 mm (0.0009 - 0.0023 in)

SEM724B

SEM725B

COMBUSTION CHAMBER REPLACEMENT

SEM720B

Usually combustion chambers should not be removed. However, if they show cracks or extensive damage, they should be replaced. 1. Remove glow plug connecting plate, glow plugs and injection nozzle. 2. Heat cylinder head in oil to between 150 and 160°C (302 and 320°F). 3. Remove combustion chamber so that cylinder head will not be damaged. Be careful not to scratch inside of nozzle hole.

4. a. b.

.

Install combustion chamber. Heat cylinder head 150 to 160°C (302 to 320°F) in oil. Align combustion chamber knock pin with cylinder head notch, and install it into cylinder head using a plastic-tip hammer.

SEM721B

EM-146

CD20T

CYLINDER HEAD

Inspection (Cont’d)

CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.

CAMSHAFT END PLAY 1. 2. 3. SEM726B

Install camshaft in cylinder head. Tighten bracket bolts to the specified torque. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in)

CAMSHAFT RUNOUT 1.

2.

Measure camshaft runout at the center journal. Runout (Total indicator reading): Limit 0.05 mm (0.0020 in) If it exceeds the limit, replace camshaft.

SEM155

CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. Cam height: Standard Unit: mm (in)

2. .

Intake

48.70 - 48.75 (1.9173 - 1.9193)

Exhaust

49.15 - 49.20 (1.9350 - 1.9370)

If wear is beyond the limit, replace camshaft.

SEM730B

CAMSHAFT JOURNAL CLEARANCE Using micrometer 1.

Measure the inner diameter of camshaft bearings. Standard inner diameter: 30.000 - 30.021 mm (1.1811 - 1.1819 in) Tighten bracket bolts to the specified torque.

.

SEM727B

2.

Measure the outer diameter of camshaft journals. Standard outer diameter: 29.935 - 29.955 mm (1.1785 - 1.1793 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Standard clearance: 0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit: 0.1 mm (0.004 in)

SEM728B

EM-147

CYLINDER HEAD

CD20T

Inspection (Cont’d)

Using plastigage 1. 2. 3.

Wipe off oil from camshaft journal bracket caps and brackets. Install camshaft in journal bracket caps and put plastigage on each camshaft journal. Install cam bracket caps and tighten cam bracket cap nuts in the correct order to the specified torque. : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

SEM879

4.

5. I

Remove cam bracket caps and measure maximum width of plastigage. Camshaft bearing clearance: Limit 0.1 mm (0.004 in) If clearance appears to exceed the limit, replace camshaft or cylinder head. Which parts to be replaced should be decided upon after measuring the diameters of the parts concerned.

SEM880

Valve clearance Checking Check valve clearance while engine is warm and not running. 1. Remove rocker cover. 2. Set No. 1 cylinder at TDC on its compression stroke. I Align pointer with TDC mark on crankshaft pulley. 1 and p 2 are loose and valve I Check that valve lifters No. p lifters No. p 7 and p 8 are tight. SEM369F

If not, turn crankshaft one revolution (360°) and align as described above.

3.

Check valve clearances of valve lifter No. 6 . p

SMA406A

EM-148

1 , p 2 , p 4 p

and

CYLINDER HEAD

CD20T Checking (Cont’d)

I I

Feeler gauge

Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance for checking (Hot): Intake 0.25 - 0.35 mm (0.010 - 0.014 in) Exhaust 0.39 - 0.49 mm (0.015 - 0.019 in)

SEM634F

3. 4. I 5. I

Turn crankshaft one revolution (360°) until No. 4 cylinder is at TDC on its compression stroke. Check valve clearances of valve lifter No. p 3 , p 5 , p 7 and 8 . p Use the same procedure as mentioned in step 3. If all valve clearances are within specification, install the following parts: Rocker cover

SMA406A

Adjusting

Face directly upwards.

Adjust valve clearance while engine is cold. 1. Turn crankshaft. Position cam lobe upward on camshaft for valve that must be adjusted.

Notch .

SEM636F

Tool (B) KV10115120

Tool (A) KV10115110

.

SEM637F

2. Place Tool (A) around camshaft as shown in figure. Before placing Tool (A), rotate notch toward center of cylinder head. (See figure.) This will simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A). 3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down. 4. Place Tool (B) between camshaft and valve lifter to retain valve lifter. CAUTION: I Tool (B) must be placed as close to camshaft bracket as possible. I Be careful not to damage cam surface with Tool (B). 5. Remove Tool (A).

EM-149

CD20T

CYLINDER HEAD Adjusting (Cont’d)

6. 7.

Small screwdriver

I I

Magnetic finger SEM638F

Remove adjusting shim using a small screwdriver and a magnetic finger. Determine replacement adjusting shim size using the following formula. Use a micrometer to determine thickness of removed shim. Calculate thickness of new adjusting shim so valve clearance comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance S = Standard valve clearance (neutral value for calculation) Unit: mm (in)

HOT COLD

SEM145D

Shim

Intake

0.30 (0.012)

Exhaust Intake Exhaust

0.44 (0.017) 0.25 (0.010) 0.38 (0.015)

Intake: N = R + [M − S] Exhaust: N = R + [M − S] Shims are available in 15 sizes from 2.20 mm (0.0866 in) to 2.90 mm (0.1142 in), in steps of 0.05 mm (0.0020 in). I Select the closest size shim to the calculated thickness. Refer to chart in SDS, EM-198.

Indicate T1 = 2.800 mm (0.1102 in) AEM236

8. I

Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down. 9. Place Tool (A) as explained in steps 2 and 3. 10. Remove Tool (B). 11. Remove Tool (A). 12. Recheck valve clearance. Valve clearance: Unit: mm (in)

Intake Exhaust

For adjusting Hot Cold* (reference data) 0.25 - 0.35 0.20 - 0.30 (0.010 - 0.014) (0.008 - 0.012) 0.39 - 0.49 0.33 - 0.43 (0.015 - 0.019) (0.013 - 0.017)

*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.

EM-150

CYLINDER HEAD

CD20T Assembly

Assembly Painted side Cylinder head side

Narrow pitch

Wide pitch

SEM202

1. Install valve component parts. Install valve spring with its narrow pitch side toward cylinder head side. I Always install new valve oil seals. Refer to oil seal replacement. I Before installing oil seal, install valve-spring seat. I When installing valve, apply engine oil on the valve stem and lip of valve oil seal. I Check whether the valve face is free from foreign matter. I I I I

Install valve spring retainers on the intake side and valve rotators on the exhaust side. Valve rotators cannot be disassembled. Install valve shims Adjust valve clearance

SEM731BA

2. Grade number Tightening sequence

I I I I

Facing front of engine (position 2) SEM528D

17.5 (0.689)

Install camshaft and brackets and tighten bracket nuts to the specified torque in two or three stages. Camshaft-bracket nuts: : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb) Tighten bracket from center to outside. Apply sealant to brackets No. 1 and No. 5. When installing brackets, set camshaft so that the pin of camshaft front head is uppermost. Install new camshaft oil seals. Refer to oil seal replacement.

13.0 (0.512)

No. 1 journal bracket No. 5 journal bracket Unit: mm (in) SEM676D

Installation Cylinder head bolt Cylinder head

1. I I I

Washer SEM675D

2.

Install cylinder head gasket. When replacing only cylinder head gasket, install same grade gasket as the one formerly used. When replacing or repairing cylinder block, piston, connecting rod and crankshaft, select gasket referring to “Selecting cylinder head gasket”. Pay attention to the direction of the cylinder head bolt washer as shown in the figure. Install cylinder head and tighten cylinder head bolts according to the following sequence.

EM-151

CYLINDER HEAD

CD20T

Installation (Cont’d)

CAUTION: The cylinder head bolts can be reused providing dimension “A” is not exceeded. Dimension “A”: 118.7 mm (4.6732 in)

Cylinder head bolt 12 mm

“A”

NEM328

EM-152

CD20T

CYLINDER HEAD

Installation (Cont’d)

Tightening procedure

Engine front

I

SEM672D

Apply engine oil to threads and underhead seating face of each bolt. Tighten bolts in the numerical order shown in the figure and following the steps below. a 31 - 37 N·m (3.2 - 3.8 kg-m, 23 - 27 ft-lb) p b p Tighten to 180 - 190° c Completely loosen the bolts in reverse order p d p 31 - 37 N·m (3.2 - 3.8 kg-m, 23 - 27 ft-lb) e Tighten to 90 - 95° p f Tighten to 90 - 95° p

SEM848F

Marking

NEM211

3. I

Install rocker cover. Install rocker cover in the sequence shown at left.

I

Apply sealing compound (THREE-BOND No. 10 or equivalent) to both ends of brackets No. 1 and No. 5.

SEM678D

Apply sealant.

SEM677D

EM-153

CD20T

CYLINDER HEAD Installation (Cont’d)

Selecting cylinder head gasket

SEM593A

When replacing only cylinder head gasket, install the same grade (Number of notches) gasket as the one formerly used. Step 1 Measure projection of piston to cylinder head surface. a) Set dial gauge and needle on cylinder block and adjust dial gauge to zero. b) Set dial gauge needle at measuring point on piston, taking care not to disturb its zero setting. c) Rotate crankshaft around the top dead center position. d) e)

25 25 (0.98) (0.98)

30 30 (1.18) (1.18)

Unit: mm (in) SEM529D

Record the maximum value. Reset dial gauge on cylinder block and confirm that zero setting has not been disturbed during measurement. f) Repeat steps b through d for all measuring points as illustrated and for each cylinder. I Be sure that piston whose projection is being measured is at its TDC. Step 2 Calculate the average value of measurements taken for each piston. Step 3 Calculate the average value of measurements for all pistons from the values obtained from step 2. Step 4 Round off the value obtained. Step 5 Determine required thickness of gasket, referring to chart A.

Relation between piston average projection and cylinder head gasket (Chart A)

Notch

Average value of piston projections mm (in)

SEM530D

Gasket thickness mm (in)

Grade (Number of notches)

New parts

In assembly

Less than 0.505 (0.0199)

1.30 (0.0512)

1.15±0.05 (0.0453±0.0020)

1

0.505 - 0.555 (0.0199 - 0.0219)

1.35 (0.0531)

1.20±0.05 (0.0472±0.0020)

2

Over 0.555 (0.0219)

1.40 (0.0551)

1.25±0.05 (0.0492±0.0020)

3

Step 6 Check if the average value of each projection obtained from step 2 is larger than the max. value of the standard projection (of selected gasket) incremented by 0.05 mm (0.0020 in). If so, use gasket that is 1 grade thicker. If not, use gasket as selected in step 4.

EM-154

CD20T

CYLINDER HEAD

Installation (Cont’d)

Example Unit: mm (in) Cylinder No. Step Item 1.

Measured value

2.

Average value of each piston

3.

Average value of all pistons

4.

Round off value

5.

Determined gasket thickness (Temporarily)

1 M1

M2

2 M3

M4

M1

M2

3 M3

M4

M1

M2

4 M3

M4

M1

M2

M3

M4

0.53 0.56 0.53 0.56 0.59 0.55 0.59 0.55 0.53 0.58 0.57 0.54 0.58 0.51 0.52 0.57 (0.0209) (0.0220) (0.0209) (0.0220) (0.0232) (0.0217) (0.0232) (0.0217) (0.0209) (0.0228) (0.0224) (0.0213) (0.0228) (0.0201) (0.0205) (0.0224) 0.545 (0.0215)

0.570 (0.0224)

0.555 (0.0219)

0.545 (0.0215)

0.55375 (0.02180) 0.554 (0.0218)*1

1.20 (0.0472) (Grade 2)

X: Maximum value of standard projection of selected gasket . . . 0.555 (0.0219) (in chart A) + 0.05 (0.0020) = 0.605 (0.0238) 6. Y: Maximum value in step 2 = 0.57 (0.0224) The relationship between X and Y is “X > Y”. *2 Determined 7. gasket thickness (Finally)

1.20 (0.0472) (Grade 2)*2

*1: If the average value of projections for all pistons is, for example, 0.553 (7) 5, as shown in the table above, it should be rounded off as follows: If the digit in the fourth decimal place (which is enclosed by a circle in this case) is smaller than 5, the average value should be regarded as 0.553 mm (0.0218 in); if it is larger than 5, the average value should be regarded as 0.554 mm (0.0218 in). *2: If X < Y, then the thicker grade 3 gasket must be used.

EM-155

TURBOCHARGER

CD20T

Removal

Removal

.

.

.

Turbocharger water return tube

1. 2. 3. 4. 5.

Disconnect radiator lower hose and drain coolant. Drain coolant from cylinder block. Remove engine under cover. Remove front exhaust tube. Remove air inlet hose from turbocharger unit.

6.

Remove connector bolts of turbocharger oil feed tube and hoses for turbocharger water feed and return tubes.

7. 8. 9.

Remove EGR tube. Remove exhaust manifold cover. Remove insulator.

Turbocharger water feed tube

Turbocharger oil feed tube

NEM204

EGR tube Air inlet hose

Exhaust manifold cover

Insulator

NEM202

10. Remove turbocharger oil return hose from oil pan. .

Turbocharger oil return hose

.

Oil pan .

NEM203

11. Remove exhaust manifold fixing nuts and bolts.

3 p

1 p

4 p

2 p

Loosen in numerical order NEM205

EM-156

CD20T

TURBOCHARGER

Removal (Cont’d)

12. Remove exhaust manifold with turbocharger unit.

Exhaust manifold

Turbocharger NEM206

Disassembly

Turbocharger water feed tube

1.

Remove oil tubes and water tubes. Before removing tubes, put mating marks on tube connectors and turbocharger.

2.

Unbend locking plates for turbocharger unit fastening nuts.

3.

Remove exhaust outlet cover, exhaust outlet, and heat insulator brackets.

4.

Remove exhaust manifold from turbocharger unit.

Turbocharger water return tube Turbocharger oil feed tube

Turbocharger oil return tube NEM207

Exhaust manifold side

Turbocharger side SEM367F

SEM026F

NEM208

EM-157

CD20T

TURBOCHARGER Inspection

Inspection Perform the following checks. If NG, replace turbocharger unit.

Check for cracks Actuator rod

Wastegate valve actuator

Compressor wheel Wastegate valve Compressor housing

Center housing

Check for leaks Check for leaks Turbine wheel Check for leaks

Turbine housing SEM366F

OIL AND WATER TUBES Check tubes for clogging.

SEM029F

ROTOR SHAFT 1.

Check rotor shaft for smooth rotation.

SEM030F

EM-158

CD20T

TURBOCHARGER

Inspection (Cont’d)

2.

Check rotor shaft for carbon deposits.

3.

Measure rotor shaft runout. Runout (Total indicator reading): Standard 0.056 - 0.127 mm (0.0022 - 0.0050 in)

4.

Measure rotor shaft end play. End play: Standard 0.013 - 0.097 mm (0.0005 - 0.0038 in) Do not allow wheels to turn when axial play is being measured.

Rotor shaft

.

SEM031F

SEM032F

I

SEM827D

TURBINE WHEEL Check turbine wheel for the following: I Oil I Carbon deposits I Deformed fins I Contact with turbine housing

SEM828D

COMPRESSOR WHEEL Check compressor wheel for the following: I Oil I Deformed fins I Contact with compressor housing

SEM829D

EM-159

TURBOCHARGER

CD20T

Inspection (Cont’d)

WASTEGATE VALVE Remove rod pin and check wastegate valve for cracks, deformation and smooth movement. Check valve seat surface for smoothness.

SEM830D

WASTEGATE VALVE ACTUATOR Apply compressed air to wastegate valve actuator and check it for smooth movement. I Do not apply compressed air to the actuator continuously. I The air pressure should be in the range of 73.3 to 101.3 kPa (733 to 1,013 mbar, 550 to 760 mmHg, 21.65 to 29.92 inHg).

SEM831D

Assembly

Small hanging flap

Assembly is the reverse order of disassembly. I Install gasket between exhaust manifold and turbocharger with small hanging flap side facing exhaust manifold.

NEM228

I Exhaust manifold side

Bend locking plates along the side of turbocharger fastening nuts. Always use new locking plates.

Turbocharger side SEM367F

Installation 1. 2 p

4 p

Install exhaust manifold fixing nuts.

1 p

3 p

Tighten in numerical order NEM209

EM-160

TURBOCHARGER

CD20T Installation (Cont’d)

2. I

Turbocharger water feed tube

Turbocharger water return tube

Installation is the reverse order of removal. Install oil tubes and water tubes in the following order, aligning the mating marks. a. Oil feed tube b. Water return tube c. Water feed tube d. Oil return tube

Turbocharger oil feed tube

Turbocharger oil return tube NEM207

EM-161

CD20T

ENGINE REMOVAL 43 - 55 (4.4 - 5.6, 32 - 41)

SEC. 112

43 - 55 (4.4 - 5.6, 32 - 41)

Rear engine mounting

64 - 74 (6.5 - 7.5, 47 - 54)

64 - 74 (6.5 - 7.5, 47 - 54)

49 - 59 (5.0 - 6.0, 36 - 44)

43 - 55 (4.4 - 5.6, 32 - 41)

62 - 78 (6.3 - 8.0, 46 - 58) Front mounting bracket

49 - 59 (5.0 - 6.0, 36 - 44)

Insulator

77 - 98 (7.9 - 100, 57 - 72)

49 - 59 (5.0 - 6.0, 36 - 44)

77 - 98 (7.9 - 100, 57 - 72)

43 - 55 (4.4 - 5.6, 32 - 41)

: N·m (kg-m, ft-lb) NEM226

EM-162

ENGINE REMOVAL

CD20T

WARNING: I Situate vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled down. I For safety during subsequent steps, the tension of wires should be slackened against the engine. I Before removing front axle from transaxle, place safety stands under designated front supporting points. Refer to GI section for lifting points and towing. I Be sure to hoist engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG or Eurofast. CAUTION: I When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. I Always use engine slingers when hoisting the engine. I When removing drive shaft, be careful not to damage transaxle oil seal. 1. 2. 3. 4. 5. 6. 7.

.

SEM531D

8. 9.

10. 11. 12. 13. 14.

Remove engine undercovers and splash covers. Remove front exhaust tube. Disconnect lower water hose from radiator and drain coolant. Drain transaxle oil. Remove power steering mounting bolt. (See left.) Drain coolant from cylinder head. Disconnect water hoses and electrical wiring from radiator and remove radiator. Disconnect fuel tubes and vacuum tubes. Release power steering belt adjusting nut and remove power steering pump from engine. Bind pump properly to the vehicle. Remove A/C compressor. Disconnect or remove electrical wiring where necessary. Release clutch lever cable. Release tachometer cable from transaxle housing. Remove front wheels.

15. Remove brake caliper mounting bolts and bind caliper properly to vehicle LH & RH.

SEM532D

EM-163

ENGINE REMOVAL 16. 17. 18. 1) 2)

CD20T

Disconnect tie rod ball joints and lower ball joints (LH & RH). Remove stabilizer. Remove drive shafts from transaxle. RH: Split drive shaft center thrust bearing. RH & LH: Remove hub mounting bolts and remove drive shaft carefully from transaxle.

19. Mount suitable slingers to cylinder head. Use a suitable hoist to release the force on the engine mountings.

SEM534D

20. Remove upper mounting (Right side).

SEM535D

21. Release transaxle shift linkages.

SEM536D

22. Release left engine mounting.

EM-164

ENGINE REMOVAL 23. Remove center member fixing bolts from chassis.

SEM538D

24. Remove engine with transaxle as shown.

.

SEM247D

EM-165

CD20T

CD20T

CYLINDER BLOCK Components

Components SEC. 110⋅120 30 - 40 (3.1 - 4.1, 266 - 354)

16 - 21 (1.6 - 2.1, 12 - 15) 30 - 40 (3.1 - 4.1, 22 - 30) 54 - 74 (5.5 - 7.5, 40 - 54)

83 - 93 (8.5 - 9.5, 61 - 69)

30 - 40 (3.1 - 4.1, 22 - 30)

8.4 - 11.0 (0.86 - 1.12, 74.35 - 97.36)

30 - 40 (3.1 - 4.1, 22 - 30)

16 - 21 (1.6 - 2.1, 12 - 15)

69 - 78 (7.0 - 8.0, 51 - 58)

: Do not re-use. : N·m (kg-m, in-lb) üü

: N·m (kg-m, ft-lb)

ü

: Lubricate with new engine oil.

1 p 2 p 3 p 4 p 5 p 6 p 7 p

Piston ring Piston Piston pin Connecting rod bearing Connecting rod Main bearing cap Rear plate

Refer to “Assembly” NEM376 8 p 9 p 10 p 11 p 12 p 13 p 14 p

Flywheel Rear oil seal Rear oil seal retainer Gusset Cylinder block Main bearing Crankshaft

EM-166

15 p 16 p 17 p 18 p 19 p 20 p

Main bearing Gusset Drain plug Pilot bushing Plate Oil jet

CD20T

CYLINDER BLOCK

Preparation

Preparation I

Drill a hole into the attachment (KV10108101).

SEM707D

Disassembly PISTON AND CRANKSHAFT

SEM895

Piston with connecting rod

Heater

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

When disassembling piston and connecting rod, heat piston to 60 to 70°C (140 to 158°F) or use piston pin press stand at room temperature.

SEM360D

8. Remove main bearing cap and crankshaft. Place the bearings and caps in their proper order. Upper bearings (cylinder block side) have oil groove.

Engine front

Loosen in numerical order

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

SEM359F

9.

Remove piston rings with a tool.

SEM291

EM-167

CD20T

CYLINDER BLOCK Inspection

Inspection PISTON AND PISTON PIN CLEARANCE 1.

Measure outer diameter of piston pin and inner diameter of piston pin hole. 2. Calculate piston to piston pin clearance. Pin diameter: 27.994 - 28.000 mm (1.1021 - 1.1024 in) Pin hole diameter: 27.991 - 27.999 mm (1.1020 - 1.1023 in) Clearance: −0.004 to 0 mm (−0.0002 to 0 in) (Interference fit) Service parts are available as a set of piston and piston pin.

PISTON RING SIDE CLEARANCE NG

Side clearance: Unit: mm (in)

Feeler gauge OK

Feeler gauge Ring

Standard

Limit

Top ring

0.020 - 0.040 (0.0008 - 0.0016)

0.10 (0.0039)

2nd ring

0.050 - 0.085 (0.0020 - 0.0033)

0.10 (0.0039)

Oil ring

0.030 - 0.070 (0.0012 - 0.0028)

0.10 (0.0039)

SEM024AA

If out of specification, replace piston and/or piston ring assembly.

EM-168

CD20T

CYLINDER BLOCK

Inspection (Cont’d)

PISTON RING END GAP

Piston Press-fit

End gap: Feeler gauge

Unit: mm (in)

Ring

Ring

SEM599A

Standard

Limit

Top ring

Bore grade 1, 2, 3 0.22 - 0.32 (0.0087 - 0.0126) Bore grade 4, 5 0.12 - 0.22 (0.0047 - 0.0087)

1.0 (0.039)

2nd ring

0.38 - 0.53 (0.0150 - 0.0209)

0.7 (0.028)

Oil ring

0.30 - 0.55 (0.0118 - 0.0217)

0.6 (0.024)

I

If out of specification, replace piston ring. If gap exceeds maximum limit with new ring, rebore cylinder and use oversize piston and piston rings. Refer to SDS (EM-199). I When replacing the piston, check the cylinder block surface for scratches or evidence of seizure. If scratches or evidence of seizure is found, hone or replace the cylinder block.

MAIN BEARING CLEARANCE 1. Install main bearings to cylinder block and main bearing cap. 2. Install main bearing cap with bearing to cylinder block. Tighten all bolts in two or three stages. : 69 - 78 N·m (7.0 - 8.0 kg-m, 51 - 58 ft-lb) 3. Measure inside diameter “A” of main journal.

SEM360F

4.

5.

I

Measure outside diameter “Dm” of main journal of crankshaft. Journal diameter: Refer to SDS (EM-199). Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.039 - 0.065 mm (0.0015 - 0.0026 in) If it exceeds the limit, replace the bearing.

SEM506A

EM-169

CD20T

CYLINDER BLOCK Inspection (Cont’d)

I I

Counter weight

I

Main journal

.

Maintain more than 0.13 mm (0.0051 in)

If crankshaft main journal is worn or shows any abnormality, regrind crank journal and use undersized bearings to maintain the specified oil clearance. Refer to SDS for regrinding crankshaft journal diameter and available service parts (EM-200). When regrinding crankshaft journal, do not grind fillet-roll.

SEM566B

I

If either bearing, crankshaft or cylinder block is replaced with a new one, select main bearing according to the following table. These numbers are punched in either Arabic or Roman numerals.

Crankshaft main journal grade number

0 1 2

Main bearing housing grade number 0 1 2 Main bearing grade number 0 1 2 1 2 3 2 3 4

Identification color: Grade 0

Yellow

Grade 1

Green

Grade 2

Brown

Grade 3

Black

Grade 4

Blue

SEM706DA

For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 Main bearing thickness: Refer to SDS (EM-200).

SEM706A

CONNECTING ROD BEARING CLEARANCE (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap with bearing to connecting rod. Apply oil to the threaded portion of bolts and seating surface of nuts. : 37 - 45 N·m (3.8 - 4.6 kg-m, 27 - 33 ft-lb) 3. Measure inside diameter “C” of bearing.

Inside micrometer

AEM027

EM-170

CD20T

CYLINDER BLOCK

Inspection (Cont’d)

4. 5. Counter weight

Pin journal

.

Maintain more than 0.13 mm (0.051 in) SEM361D

I I I I

Measure outside diameter “Dp” of crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.031 - 0.055 mm (0.0012 - 0.0022 in) If it exceeds the limit, replace the bearing. If crankshaft pin journal is worn or shows any abnormality, regrind crank pin and use undersized bearings to maintain the specified oil clearance. Refer to SDS for regrinding diameter of crankshaft pin and available service parts (EM-200). When regrinding crankshaft pin, do not grind fillet-roll.

Selective connecting rod bearing I If either bearings or crankshaft are being replaced with new ones, select connecting rod bearings according to the following table. Grade numbers are punched in either Arabic or Roman numerals. Crankshaft pin journal grade number

Connecting rod bearing grade number

SEM705D

0

1

2

0

1

2

Identification color Grade 0: Black Grade 1: Yellow Grade 2: Blue

CONNECTING ROD AND PISTON PIN CLEARANCE (Small end) I

Clearance (D − d): 0.025 - 0.044 mm (0.0010 - 0.0017 in) If clearance exceeds the specifications, replace the bearing.

Clearance = D − d SEM575B

EM-171

CYLINDER BLOCK

CD20T

Inspection (Cont’d)

Bearing replacement I Remove bearing with a suitable tool. Do not scratch inner surface of connecting rod.

SEM906

1. 2.

Install new bearing with oil holes aligned correctly. Ream bore using a suitable tool. Ream bore: 28.025 - 28.038 mm (1.1033 - 1.1039 in)

SEM907

CONNECTING ROD BEND AND TORSION Bend and torsion [per 100 mm (3.94 in) length]: Bend Less than 0.025 mm (0.0010 in) Torsion Less than 0.025 mm (0.0010 in)

EM133

CRANKSHAFT 1. 2.

Taper:

Check crankshaft journals and pins for score, bias, wear or cracks. If faults are minor, correct with fine emery paper. Check journals and pins with a micrometer for taper and outof-round. Out-of-round (X − Y): Less than 0.005 mm (0.0002 in) Taper (A − B): Less than 0.005 mm (0.0002 in)

Out-of-round: SEM316A

3.

.

Check crankshaft runout. Runout (Total indicator reading): Less than 0.05 mm (0.0020 in)

SEM601A

EM-172

CD20T

CYLINDER BLOCK

Inspection (Cont’d)

CYLINDER BLOCK DISTORTION Clean upper face of cylinder block and measure the distortion. Limit: 0.10 mm (0.0039 in) If out of specification, resurface it. The resurfacing limit of cylinder block is determined by cylinder head resurfacing in an engine.

Measuring points

Warpage of surface: Less than 0.1 mm (0.004 in)

SEM655A

H = 227.75-227.85 mm (8.9665-8.9705 in)

Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.1 mm (0.004 in) Nominal cylinder block height from crankshaft center: 227.75 - 227.85 mm (8.9665 - 8.9705 in) If necessary, replace cylinder block.

NEM210

CYLINDER BORE 1. 2.

Check for scratches or seizure. If seizure is found, hone bore. Using a bore gauge, measure cylinder bore for wear, out-ofround or taper. Standard bore diameter: 84.500 - 84.550 mm (3.3268 - 3.3287 in) Unit: mm (in)

Bore wear limit

0.2 (0.008)

Out-of-round (X − Y) standard

0.015 (0.0006)

Taper (A − B) standard

0.010 (0.0004)

If it exceeds the limit, rebore all four cylinders. Replace cylinder block if necessary. If cylinder block or piston is replaced, match piston grade with grade number on cylinder block upper surface.

SEM704DA

EM-173

CYLINDER BLOCK

CD20T

Inspection (Cont’d)

Piston grade number

Front SEM176B

Reboring 1.

SEM904-A

The size to which cylinders must be honed, is determined by adding piston-to-cylinder clearance to the piston skirt diameter “A”. Dimension “a”: Approximately 62 mm (2.44 in) Rebored size calculation D = A + B − C = A + [0.03 to 0.05 mm (0.0012 to 0.0020 in)] where, D: Honed diameter A: Skirt diameter as measured B: Piston-to-wall clearance C: Machining allowance 0.02 mm (0.0008 in) 2. Install main bearing caps and tighten bolts to the specified torque. This will prevent distortion of cylinder bores. 3. Cut cylinder bores in the order of 2-4-1-3. Do not cut too much out of the cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 4. Hone the cylinders to the required size referring to SDS (EM199). 5. Measure the finished cylinder bore for out-of-round and taper. Measurement of a just machined cylinder bore requires utmost care since it is expanded by cutting heat.

PISTON-TO-BORE CLEARANCE Using micrometer 1.

2.

Measure piston and cylinder bore diameter. Piston diameter “A”: Refer to SDS (EM-199). Measuring point “a” (Distance from the bottom): Approximately 62 mm (2.44 in) Bore diameter “D”: Refer to SDS (EM-199). Measuring point (Distance from the top): Approximately 70 mm (2.76 in) Check that piston clearance is within the specification. Piston clearance (D − A): 0.030 - 0.050 mm (0.0012 - 0.0020 in)

EM-174

CD20T

CYLINDER BLOCK

Inspection (Cont’d)

Using feeler gauge 1. 2.

Set piston and feeler gauge with spring scale. Measure extracting force while pulling up scale slowly. Feeler gauge used: 0.05 - 0.07 mm (0.0020 - 0.0028 in) Extracting force: 7.8 - 14.7 N (0.8 - 1.5 kg, 1.8 - 3.3 lb)

SEM550

Assembly PISTON I

Numbers stamped on connecting rod and cap correspond to each cylinder. Care should be taken to avoid a wrong combination including bearing and connecting rod direction.

I I

Install new snap ring on one side of piston pin hole. When assembling piston and connecting rod with piston pin, heat piston to between 60 and 80°C (140 and 176°F) and install piston pin with a suitable tool. Install new snap ring. After assembling, ascertain that piston swings smoothly.

SEM703D

I I

EM156

Punch mark side up

I Install piston rings with a suitable tool. Selective top ring; When installing new top ring or replacing cylinder block, select top ring to adjust ring gap.

Teflon tube set position

Cylinder bore grade

Top ring grade No.

1, 2, 3

4, 5

No mark

S

SEM251D

CRANKSHAFT 1. I I I Front

Set main bearings in the proper position on cylinder block and main bearing caps. If either crankshaft, cylinder block or main bearing is reused again, it is necessary to measure main bearing clearance. Upper bearings (cylinder block side) have oil groove. Apply new engine oil to bearing surfaces.

SEM617

EM-175

CYLINDER BLOCK

CD20T

Assembly (Cont’d) Bearing No.

2. 3. 4. I I

Engine front NEM377

I I

Engine front

Tighten in numerical order.

Apply engine oil to main bearing surfaces on crankshaft journal side. Install crankshaft and main bearing caps. Tighten main bearing cap bolts. : 69 - 78 N·m (7.0 - 8.0 kg-m, 51 - 58 ft-lb) Arrange the parts so that the indicated numbers on bearing caps are in a row from the front of engine. Tighten bearing cap bolts gradually in two or three stages and outwardly from center bearing in sequence. After securing bearing cap bolts, ascertain that crankshaft turns smoothly. Apply new engine oil to threads of bearing cap bolts.

SEM362F

5. Feeler gauge

Measure crankshaft free end play at center bearing. Crankshaft free end play: Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.30 mm (0.0118 in)

SEM363F

PISTON WITH CONNECTING ROD

Align oil hole.

1.

Install connecting rod bearings in the connecting rods and connecting rod caps. I Confirm that correct size of bearings is used. Refer to “Inspection” (EM-170). I Install the bearings so that the oil hole in the connecting rod aligns with the oil hole of the bearing. I Apply engine oil to connecting rod bearing surfaces on the crankshaft journal side. SEM159B

I

Set piston rings as shown.

SEM909

EM-176

CD20T

CYLINDER BLOCK

Assembly (Cont’d)

2. I I

EM03470000 or suitable tool

I I

Install pistons with connecting rods. Install them into corresponding cylinder using Tool. Be careful not to scratch cylinder wall with connecting rod. Apply engine oil to cylinder wall, piston and bearing. Arrange so that the front mark on piston head faces to the front of engine.

SEM620-A

3. I

KV10112100

SEM364F

Install connecting rod bearing caps. Apply engine oil to the thread of connecting rod bearing nut. (1) Tighten connecting rod bearing nut to 15±1 N·m (1.5±0.1 kg-m, 10.8±0.7 ft-lb). (2) Then tighten an additional 60+5° −0° turns with an angular tightening wrench. : 15±1 N·m (1.5±0.1 kg-m, 11±0.7 ft-lb) plus 60+5° −0° or : 37 - 45 N·m (3.8 - 4.6 kg-m, 27 - 33 ft-lb) 4.

Feeler gauge

Measure connecting rod side clearance. Connecting rod side clearance (Big end play): Limit 0.3 mm (0.012 in)

SEM365F

FLYWHEEL RUNOUT Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)

EM426

EM-177

QG

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications Engine

NCEM0028

QG16DE

QG18DE

Classification

Gasoline

Cylinder arrangement

4, in-line

Displacement cm3 (cu in)

1,596 (97.39)

1,769 (107.94)

Bore × stroke mm (in)

76.0 × 88.0 (2.992 × 3.465)

80.0 × 88.0 (3.150 × 3.465)

Valve arrangement

DOHC

Firing order

1-3-4-2 Compression

2

Oil

1

Number of piston rings Number of main bearings

5

Compression ratio

9.5

EM120

a

b

c

d

e

f

QG16DE

222°

228°

-4° (16°)

52° (32°)

−2°

44°

QG18DE

222°

236°

0° (20°)

56° (36°)

−2°

44°

Valve timing

(

): Valve timing control ON

Compression Pressure

NJEM0029

Unit: kPa (bar, kg/cm2, psi)/350 rpm Standard

1,324 (13.24, 13.5, 192)

Minimum

1,128 (11.28, 11.5, 164)

Difference limit between cylinders

98 (0.98, 1.0, 14)

Cylinder Head

NCEM0030

Unit: mm (in)

Head surface flatness Height

Standard

Limit

Less than 0.03 (0.0012)

0.1 (0.004)

117.8 - 118.0 (4.638 - 4.646)

—

EM-178

QG

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve

Valve

NCEM0031

VALVE

NCEM0031S01

Unit: mm (in) T (Margin thickness)

SEM188A

Intake

29.9 - 30.2 (1.177 - 1.189)

Exhaust

24.9 - 25.2 (0.980 - 0.992)

Valve head diameter “D” Intake

92.00 - 92.50 (3.6220 - 3.6417)

Exhaust

92.37 - 92.87 (3.6366 - 3.6563)

Intake

5.465 - 5.480 (0.2152 - 0.2157)

Exhaust

5.445 - 5.460 (0.2144 - 0.2150)

Valve length “L”

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

45°15′ - 45°45′

Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface grinding limit

0.2 (0.008)

VALVE SPRING

NCEM0031S02

Free height mm (in)

40.0 (1.575) Standard

370.0 (37.73, 83.19) at 23.64 (0.9307)

Limit

347.8 (35.46, 78.19) at 23.64 (0.9307)

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

Less than 1.75 (0.0689)

VALVE LIFTER

NCEM0031S10

Unit: mm (in) Valve lifter outside diameter

29.960 - 29.975 (1.1795 - 1.1801)

Lifter guide inside diameter

30.000 - 30.021 (1.1811 - 1.1819)

Clearance between valve lifter and valve lifter guide

0.025 - 0.061 (0.0010 - 0.0024)

VALVE CLEARANCE

NCEM0031S11

Unit: mm (in) For adjusting

For checking

Hot

Cold* (reference data)

Hot

Intake

0.32 - 0.40 (0.013 - 0.016)

0.25 - 0.33 (0.010 - 0.013)

0.21 - 0.49 (0.008 - 0.019)

Exhaust

0.37 - 0.45 (0.015 - 0.018)

0.32 - 0.40 (0.013 - 0.016)

0.30 - 0.58 (0.012 - 0.023)

*: At a temperature of approximately 20°C (68°F) Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust again if necessary.

EM-179

QG

SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d)

VALVE GUIDE

NCEM0031S04

Unit: mm (in)

MEM096A

Intake

Outer diameter

Exhaust

Standard

Service

Standard

Service

9.523 - 9.534 (0.3749 - 0.3754)

9.723 - 9.734 (0.3828 - 0.3832)

9.523 - 9.534 (0.3749 - 0.3754)

9.723 - 9.734 (0.3828 - 0.3832)

Valve guide Inner diameter [Finished size]

5.500 - 5.515 (0.2165 - 0.2171)

5.500 - 5.515 (0.2165 - 0.2171)

Cylinder head valve guide hole diameter

9.475 - 9.496 (0.3730 - 0.3739)

Interference fit of valve guide

0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 - 0.027 - 0.059 (0.0011 - 0.027 - 0.049 (0.0011 0.0023) 0.0019) 0.0023) 0.0019)

Stem to guide clearance

9.685 - 9.696 (0.3813 - 0.3817)

9.475 - 9.496 (0.3730 - 0.3739)

0.020 - 0.050 (0.0008 - 0.0020)

Valve deflection limit (Dial gauge reading)

9.685 - 9.696 (0.3813 - 0.3817)

0.040 - 0.070 (0.0016 - 0.0028) 0.2 (0.008)

Projection length “L”

11.5 - 11.7 (0.453 - 0.461)

AVAILABLE SHIMS

NCEM0031S07

Thickness mm (in)

Identification mark

2.00 (0.0787)

2.00

2.02 (0.0795)

2.02

2.04 (0.0803)

2.04

2.06 (0.0811)

2.06

2.08 (0.0819)

2.08

2.10 (0.0827)

2.10

2.12 (0.0835)

2.12

2.14 (0.0843)

2.14

2.16 (0.0850)

2.16

2.18 (0.0858)

2.18

2.20 (0.0866)

2.20

2.22 (0.0874)

2.22

2.24 (0.0882)

2.24

2.26 (0.0890)

2.26

2.28 (0.0898)

2.28

2.30 (0.0906)

2.30

2.32 (0.0913)

2.32

EM-180

SERVICE DATA AND SPECIFICATIONS (SDS)

QG Valve (Cont’d)

Thickness mm (in)

Identification mark

2.34 (0.0921)

2.34

2.36 (0.0929)

2.36

2.38 (0.0937)

2.38

2.40 (0.0945)

2.40

2.42 (0.0953)

2.42

2.44 (0.0961)

2.44

2.46 (0.0969)

2.46

2.48 (0.0976)

2.48

2.50 (0.0984)

2.50

2.52 (0.0992)

2.52

2.54 (0.1000)

2.54

2.56 (0.1008)

2.56

2.58 (0.1016)

2.58

2.60 (0.1024)

2.60

2.62 (0.1031)

2.62

2.64 (0.1039)

2.64

2.66 (0.1047)

2.66

2.68 (0.1055)

2.68

2.70 (0.1063)

2.70

2.72 (0.1071)

2.72

2.74 (0.1079)

2.74

2.76 (0.1087)

2.76

2.78 (0.1094)

2.78

2.80 (0.1102)

2.80

2.82 (0.1110)

2.82

2.84 (0.1118)

2.84

2.86 (0.1126)

2.86

2.88 (0.1134)

2.88

2.90 (0.1142)

2.90

2.92 (0.1150)

2.92

2.94 (0.1157)

2.94

2.96 (0.1165)

2.96

2.98 (0.1173)

2.98

EM-181

QG

SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d)

Indicate T1 = 2.800 mm (0.1102 in)

Shim

AEM236

VALVE SEAT

NCEM0031S05

Unit: mm (in) INTAKE Standard

EXHAUST Standard 1.20 - 1.68 (0.0472 - 0.0661)

1.06 - 1.34 (0.0417 - 0.0528)

5.9 (0.232)

5.65 (0.2224)

Oversize 1.20 - 1.68 (0.0472 - 0.0661)

Oversize 1.06 - 1.34 (0.0417 - 0.0528)

5.65 (0.2224)

5.9 (0.232)

Cylinder head machining data Cylinder head machining data

SEM574DA

SEM573DA

Dia.

QG

Dia.

QG

A

27.8 - 28.0 (1.094 - 1.102) dia.

E

24.5 - 24.7 (0.965 - 0.972)

B

29.5 - 29.7 (1.161 - 1.169) dia.

F

26.2 - 26.4 (1.031 - 1.039)

C

31.9 - 32.1 (1.256 - 1.264)

G

26.500 - 26.516 (1.0433 - 1.0439)

D

31.500 - 31.516 (1.2402 - 1.2408)

EM-182

QG

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve (Cont’d)

VALVE SEAT RESURFACE LIMIT

NCEM0031S08

Unit: mm (in)

AEM343

Intake

35.95 - 36.55 (1.4154 - 1.4390)

Exhaust

35.92 - 36.52 (1.4142 - 1.4378)

Depth (L)

Camshaft and Camshaft Bearing

NCEM0032

Unit: mm (in) Engine model Intake

QG16DE

QG18DE

40.220 - 40.410 (1.5835 - 1.5909)

40.610 - 40.800 (1.5988 - 1.6063)

Cam height “A” Exhaust

40.056 - 40.245 (1.5770 - 1.5844)

Cam wear limit

0.20 (0.0079)

EM671

Camshaft journal to bearing clearance

Standard

Limit

0.045 - 0.086 (0.0018 - 0.0034)

0.15 (0.0059)

Inner diameter of camshaft bearing

No. 1

28.000 - 28.021 (1.1024 - 1.1032)

No. 2 to No. 5

24.000 - 24.021 (0.9449 - 0.9457)

Outer diameter of camshaft journal

No. 1

27.935 - 27.955 (1.0998 - 1.1006)

No. 2 to No. 5

23.935 - 23.955 (0.9423 - 0.9431)

Camshaft runout [TIR*] Camshaft end play

—

— Less than 0.02 (0.0008)

0.1 (0.004)

0.115 - 0.188 (0.0045 - 0.0074)

0.20 (0.0079)

*Total indicator reading

EM-183

QG

SERVICE DATA AND SPECIFICATIONS (SDS) Cylinder Block

Cylinder Block

NCEM0033

100 (3.94)

60 (2.36)

20 (0.79)

Unit: mm (in)

Crankshaft center SEM171D

QG16DE

QG18DE Limit Standard

Surface flatness Height “H” (nominal)

Cylinder bore inner diameter

Standard

Less than 0.03 (0.0012)

0.1 (0.004)

213.95 - 214.05 (8.4232 - 8.4271)

—

Grade No. 1

76.000 - 76.0610 (2.9921 - 2.9925)

80.000 - 80.010 (3.1496 - 3.1500)

Grade No. 2

76.010 - 76.020 (2.7957 - 2.7961)

80.010 - 80.020 (3.1500 - 3.1504)

Grade No. 3

76.020 - 76.030 (2.7961 - 2.9933)

80.020 - 80.030 (3.1504 - 3.1508)

0.2 (0.008)

Out-of-round (X − Y)

Less than 0.015 (0.0006)

—

Taper (A − B)

Less than 0.01 (0.0004)

—

0.05 (0.0020)

0.2 (0.008)

Difference in inner diameter between cylinders

EM-184

QG

SERVICE DATA AND SPECIFICATIONS (SDS)

Piston, Piston Ring and Piston Pin

Piston, Piston Ring and Piston Pin

NCEM0034

PISTON

NCEM0034S01

Unit: mm (in)

SEM882E

QG16DE

QG18DE

Grade No. 1

75.975 - 75.985 (2.9911 - 2.9915)

79.965 - 79.975 (3.1482 - 3.1486)

Grade No. 2

75.985 - 75.995 (2.9915 - 2.9919)

79.975 - 79.985 (3.1486 - 3.1490)

Grade No. 3

75.995 - 76.005 (2.9919 - 2.9923)

79.985 - 79.995 (3.1490 - 3.1494)

0.5 (0.002) oversize (service)

76.475 - 76.505 (3.0108 - 3.0120)

80.215 - 80.245 (3.1581 - 3.1592)

1.0 (0.039) oversize (service)

76.975 - 77.005 (3.0305 - 3.0317)

80.465 - 80.495 (3.1679 - 3.1691)

44.5 (1.7520)

42.3 (1.665)

Piston pin hole inner diameter

18.987 - 18.999 (0.7475 - 0.7080)

18.993 - 19.005 (0.7478 - 0.7482)

Piston to bore clearance

0.015 - 0.035 (0.0006 - 0.0014)

0.025 - 0.045 (0.0010 - 0.0018)

Piston skirt diameter “A”

Standard

“a” dimension

PISTON RING

NCEM0034S02

Unit: mm (in) QG16DE

QG18DE Limit Standard

Top Side clearance

0.045 - 0.080 (0.0018 - 0.0031)

2nd Oil

2nd

0.110 (0.0043)

0.030 - 0.070 (0.0012 - 0.0028) 0.065 - 0.135 (0.0026 - 0.0053)

Top End gap

0.040 - 0.080 (0.0016 - 0.0031)

0.100 (0.0039)

0.045 - 0.155 (0.0018 - 0.0061)

—

0.20 - 0.30 (0.0079 - 0.0118) 0.50 - 0.65 (0.0197 - 0.0256)

Oil

0.53 (0.0209)

0.32 - 0.47 (0.0126 - 0.0185)

0.98 (0.0386)

0.20 - 0.60 (0.0079 - 0.0236)

0.95 (0.0374)

PISTON PIN

NCEM0034S03

Unit: mm (in) QG16DE Piston pin outer diameter Piston pin to piston clearance Piston pin to connecting rod bushing clearance

QG18DE

18.989 - 19.001 (0.7476 - 0.7481) −0.004 to 0 (−0.0002 to 0) Standard

0.002 - 0.006 (0.0001 - 0.0002)

0.005 - 0.017 (0.0002 - 0.0007)

Limit

0.023 (0.0009)

EM-185

SERVICE DATA AND SPECIFICATIONS (SDS)

QG

Connecting Rod

Connecting Rod

NCEM0035

Unit: mm (in) Center distance

140.45 - 140.55 (5.5295 - 5.5335)

Bend limit [per 100 (3.94)]

0.15 (0.0059)

Torsion limit [per 100 (3.94)]

0.3 (0.012)

Connecting rod bushing inner diameter* (small end)

19.000 - 19.012 (0.7480 - 0.7485)

Connecting rod big end inner diameter

43.000 - 43.013 (1.6929 - 1.6934) Standard

0.200 - 0.470 (0.0079 - 0.0185)

Side clearance Limit

0.5 (0.020)

*After installing in connecting rod

Crankshaft

NCEM0036

Unit: mm (in)

Main journal dia. “Dm”

Pin journal dia. “Dp”

Grade No. 0

49.956 - 49.964 (1.9668 - 1.9671)

Grade No. 1

49.948 - 49.956 (1.9665 - 1.9668)

Grade No. 2

49.940 - 49.948 (1.9661 - 1.9665)

Grade No. 0

39.968 - 39.974 (1.5735 - 1.5738)

Grade No. 1

39.962 - 39.968 (1.5733 - 1.5735)

Grade No. 2

39.956 - 39.962 (1.5731 - 1.5733)

Center distance “r”

43.95 - 44.05 (1.7303 - 1.7342) Standard

Less than 0.003 (0.0001)

Limit

Less than 0.005 (0.0002)

Standard

Less than 0.004 (0.0002)

Limit

Less than 0.005 (0.0002)

Standard

Less than 0.04 (0.0016)

Limit

Less than 0.05 (0.0020)

Out-of-round (X − Y)

Taper (A − B)

Runout [TIR*] Standard

0.060 - 0.260 (0.0024 - 0.0102)

Free end play Limit

0.3 (0.012)

*: Total indicator reading

Main Bearing

NCEM0037

STANDARD

NCEM0037S01

Grade No.

Thickness “T” mm (in)

Identification color

0

1.826 - 1.830 (0.0719 - 0.0720)

Black

1

1.830 - 1.834 (0.0720 - 0.0722)

Red

2

1.834 - 1.838 (0.0722 - 0.0724)

Green

3

1.838 - 1.842 (0.0724 - 0.0725)

Yellow

4

1.842 - 1.846 (0.0725 - 0.0727)

Blue

UNDERSIZE

NCEM0037S02

Unit: mm (in) Thickness “T” 0.25 (0.0098)

1.960 - 1.964 (0.0772 - 0.0773)

0.50 (0.0197)

2.085 - 2.089 (0.0821 - 0.0822)

EM-186

QG

SERVICE DATA AND SPECIFICATIONS (SDS)

Connecting Rod Bearing

Connecting Rod Bearing

NCEM0038

STANDARD SIZE

NCEM0038S01

Unit: mm (in) Grade No.

Thickness

Identification color or number

0

1.503 - 1.506 (0.0592 - 0.0593)

—

1

1.506 - 1.509 (0.0593 - 0.0594)

Brown

2

1.509 - 1.512 (0.0594 - 0.0595)

Green

UNDERSIZE

NCEM0038S02

Unit: mm (in) Grade No.

Thickness

Identification color or number

0.08 (0.0031)

1.542 - 1.546 (0.0607 - 0.0609)

—

0.12 (0.0047)

1.562 - 1.566 (0.0615 - 0.0617)

—

0.25 (0.0098)

1.627 - 1.631 (0.0641 - 0.0642)

—

Bearing Clearance

NCEM0039

Unit: mm (in) Standard

0.020 - 0.044 (0.0008 - 0.0017)

Main bearing clearance Limit

0.1 (0.004)

Standard

0.014 - 0.039 (0.0006 - 0.0015)

Connecting rod bearing clearance Limit

0.1 (0.004)

Miscellaneous Components

NCEM0040

Unit: mm (in) Flywheel runout [TIR*]

Less than 0.15 (0.0059)

Camshaft sprocket runout [TIR*]

Less than 0.15 (0.0059)

*: Total indicator reading

EM-187

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications Cylinder arrangement cm3 (cu in)

Displacement

Valve timing

In-line 4

Bore and stroke

mm (in)

1,998 (121.92) 86 x 86 (3.39 x 3.39)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings Compression

2

Oil

1

Number of main bearings

5

Compression ratio

10.0

EM120

Unit: degree

SR20DE

a

b

c

d

e

f

232°

240°

6°

54°

3°

49°

Inspection and Adjustment COMPRESSION PRESSURE Unit: kPa (bar, kg/cm2, psi)/300 rpm Standard

1,275 (12.75, 13.0, 185)

Minimum

1,079 (10.79, 11.0, 156)

Differential limit between cylinders

98 (0.98, 1.0, 14)

CYLINDER HEAD Unit: mm (in)

Head surface distortion

Standard

Limit

Less than 0.03 (0.0012)

0.1 (0.004)

Nominal cylinder head height: H = 136.9 - 137.1 mm (5.390 - 5.398 in) SEM956C

EM-188

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

VALVE

Hydraulic lash adjuster (HLA) Unit: mm (in)

Unit: mm (in) HLA outer diameter

16.980 - 16.993 (0.6685 - 0.6690)

HLA guide inner diameter

17.000 - 17.020 (0.6693 - 0.6701)

Clearance between HLA and HLA guide

0.007 - 0.040 (0.0003 - 0.0016)

Valve guide Unit: mm (in)

SEM188

Valve head diameter “D” Intake

34.0 - 34.2 (1.339 - 1.346)

Exhaust

30.0 - 30.2 (1.181 - 1.189)

Valve length “L” Intake

98.17 - 98.63 (3.8650 - 3.8831)

Exhaust

99.09 - 99.55 (3.9012 - 3.9193)

Valve stem diameter “d” Intake

5.965 - 5.980 (0.2348 - 0.2354)

Exhaust

5.945 - 5.960 (0.2341 - 0.2346)

NEM032

Intake

45°15′ - 45°45′

Exhaust

Intake

10.023 - 10.034 (0.3946 - 0.3950)

10.223 - 10.234 (0.4025 - 0.4029)

Exhaust

10.023 - 10.034 (0.3946 - 0.3950)

10.223 - 10.234 (0.4025 - 0.4029)

Outer diameter

Valve margin “T” Intake

1.3 (0.051)

Exhaust

1.6 (0.063)

Valve margin “T” limit

More than 0.5 (0.020)

Valve stem end surface grinding limit

Less than 0.2 (0.008)

Valve guide Inner diam- Intake eter (Finished size) Exhaust Cylinder head valve guide hole diameter

Valve clearance Intake

0 (0)

Exhaust

0 (0)

mm (in)

49.36 (1.9433)

569.00 - 641.57 (58.02 - 65.42, 127.93 - 144.25) at 30.0 (1.181)

Standard

mm (in)

10.175 - 10.196 (0.4006 - 0.4014)

Exhaust

9.975 - 9.996 (0.3927 - 0.3935)

10.175 - 10.196 (0.4006 - 0.4014)

0.027 - 0.059 (0.0011 - 0.0023) Standard

Limit

Intake

0.020 - 0.053 (0.0008 - 0.0021)

0.08 (0.0031)

Exhaust

0.040 - 0.073 (0.0016 - 0.0029)

0.1 (0.004)

Valve deflection limit

0.2 (0.008)

Projection length “L”

14.0 - 14.2 (0.551 - 0.559)

549.2 (56.0, 123.5) at 30.0 (1.181)

Limit

6.000 - 6.018 (0.2362 - 0.2369)

Intake

Stem to guide clearance

Pressure N (kg, lb) at height mm (in)

6.000 - 6.018 (0.2362 - 0.2369)

9.975 - 9.996 (0.3927 - 0.3935)

Interference fit of valve guide

Valve spring

Out-of-square

Service

Valve guide

Valve seat angle “α”

Free height

Standard

Less than 2.2 (0.087)

EM-189

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)

Valve seat SR20DE engine Unit: mm (in) Cylinder head INTAKE

EXHAUST

Standard

Standard

*29.35 - 29.65 (1.1555 - 1.1673)

*44°53′ - 45°07′ *33.6 - 33.8 (1.323 - 1.331) Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)

*44°53′ - 45°07′

*29.4 -29.6 (1.157 - 1.165)

Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)

Oversize

Oversize

*44°53′ - 45°07′ *33.6 - 33.8 (1.323 - 1.331) Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552) :* Machining data

*44°53′ - 45°07′

*29.4 - 29.6 (1.157 - 1.165)

Contacting width (W): 1.385 - 1.401 (0.0545 - 0.0552)

Standard

NEM212

Service

In.

35.000 - 35.016 (1.3780 - 1.3786)

35.500 - 35.516 (1.3976 - 1.3983)

Ex.

31.000 - 31.016 (1.2205 - 1.2211)

31.500 - 31.516 (1.2402 - 1.2408)

Cylinder head seat recess diameter (D) In.

0.064 - 0.096 (0.0025 - 0.0038)

Ex.

0.064 - 0.096 (0.0025 - 0.0038)

Valve seat interference fit In.

35.080 - 35.096 (1.3811 - 1.3817)

35.580 - 35.596 (1.4008 - 1.4014)

Ex.

31.080 - 31.096 (1.2236 - 1.2242)

31.580 - 31.596 (1.2433 - 1.2439)

Valve seat outer diameter (d) In.

6.25 (0.2461)

Ex.

6.25 (0.2461)

Depth (H) Height (h)

6.2 - 6.3 (0.244 - 0.248)

EM-190

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

Valve clearance adjustment Unit: mm (in) Rocker arm guide

Valve clearance Intake

0 (0)

Exhaust

0 (0)

Valve clearance “T”

T1±0.025 (0.001)

Valve

Available shim

Valve SEM095D

Thickness mm (in)

Identification mark

2.800 (0.1102)

28 00

2.825 (0.1112)

28 25

2.850 (0.1122)

28 50

2.875 (0.1132)

28 75

2.900 (0.1142)

29 00

2.925 (0.1152)

29 25

2.950 (0.1161)

29 50

2.975 (0.1171)

29 75

3.000 (0.1181)

30 00

3.025 (0.1191)

30 25

3.050 (0.1201)

30 50

3.075 (0.1211)

30 75

3.100 (0.1220)

31 00

3.125 (0.1230)

31 25

3.150 (0.1240)

31 50

3.175 (0.1250)

31 75

3.200 (0.1260)

32 00

Shim

Indicate T = 2.800 mm (0.1102 in) SEM096D

EM-191

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)

CAMSHAFT AND CAMSHAFT BEARING

CYLINDER BLOCK

Unit: mm (in) Limit

0.030 - 0.071 (0.0012 - 0.0028)

0.15 (0.0059)

Inner diameter of camshaft bearing

28.000 - 28.021 (1.1024 - 1.1032)

—

Outer diameter of camshaft journal

27.950 - 27.970 (1.1004 - 1.1012)

—

Camshaft runout [TIR*]

Less than 0.02 (0.0008)

0.1 (0.004)

Camshaft sprocket runout [TIR*]

Less than 0.25 (0.0098)

—

Camshaft end play

0.055 - 0.139 (0.0022 - 0.0055)

0.20 (0.0079)

211.25 - 211.35 (8.3169 - 8.3208)

Standard Camshaft journal to bearing clearance

Unit: mm (in)

100 (3.94) 60 (2.36) 10 (0.39)

SEM008D

EM671

SR20DE

SEM010D

Surface flatness

Cam height “A”

Standard

Intake

37.775 (1.4872)

Exhaust

37.404 (1.4726)

Cam wear limit

Limit

Less than 0.03 (0.0012) 0.10 (0.0039)

Cylinder bore

0.2 (0.008)

Inner diameter

*Total indicator reading

Standard Grade No. 1

86.000 - 86.010 (3.3858 - 3.3862)

Grade No. 2

86.010 - 86.020 (3.3862 - 3.3866)

Grade No. 3

86.020 - 86.030 (3.3866 - 3.3870)

Wear limit

0.20 (0.0079)

Out-of-round (X − Y)

Less than 0.015 (0.0006)

Taper (A − B − C)

Less than 0.010 (0.0004)

Difference in inner diameter between cylinders Limit

Less than 0.05 (0.0020)

Main journal inner diameter

EM-192

Grade No. 0

58.944 - 58.950 (2.3206 - 2.3209)

Grade No. 1

58.950 - 58.956 (2.3209 - 2.3211)

Grade No. 2

58.956 - 58.962 (2.3211 - 2.3213)

Grade No. 3

58.962 - 58.968 (2.3213 - 2.3216)

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

PISTON, PISTON RING AND PISTON PIN

Piston pin Unit: mm (in)

Available piston Unit: mm (in)

Piston pin outer diameter Interference fit of piston pin to piston

21.989 - 22.001 (0.8657 - 0.8662) 0.002 - 0.006 (0.0001 - 0.0002)

Piston pin to connecting rod bushing clearance Standard Limit

0.005 - 0.017 (0.0002 - 0.0007) 0.023 (0.0009)

* Values measured at ambient temperature of 20°C (68°F)

CONNECTING ROD SEM750C

Piston skirt diameter “A”

Center distance

Standard 85.980 - 85.990 (3.3850 - 3.3854)

Grade No. 2

85.990 - 86.000 (3.3854 - 3.3858)

Grade No. 3

86.000 - 86.010 (3.3858 - 3.3862)

“a” dimension Piston clearance to cylinder block Piston pin hole diameter

136.30 (5.3661)

Bend, torsion [per 100 (3.94)]

Grade No. 1

0.20 (0.0079) oversize (Service)

Unit: mm (in)

Limit

0.15 (0.0059)

Torsion [per 100 (3.94)] Limit

86.180 - 86.210 (3.3929 - 3.3941) 13.1 (0.5157)

0.3 (0.0012)

Connecting rod small end inner diameter

24.980 - 25.000 (0.9835 - 0.9843)

Piston pin bushing inner diameter*

22.000 - 22.012 (0.8661 - 0.8666)

Connecting rod big end inner diameter

51.000 - 51.013 (2.0079 - 2.0084)

0.010 - 0.030 (0.0004 - 0.0012) 21.993 - 22.005 (0.8659 - 0.8663)

Side clearance Standard

Piston ring

Limit Unit: mm (in)

* After installing in connecting rod

Side clearance Top Standard Limit

0.045 - 0.080 (0.0018 - 0.0031) 0.2 (0.008)

2nd Standard Limit Oil ring

0.030 - 0.070 (0.0012 - 0.0028) 0.2 (0.008) 0.065 - 0.135 (0.0026 - 0.0053)

Ring gap Top Standard Limit

0.20 - 0.30 (0.0079 - 0.0118) 1.0 (0.039)

2nd Standard Limit

0.35 - 0.50 (0.0138 - 0.0197) 1.0 (0.039)

Oil Standard Limit

0.20 - 0.60 (0.0079 - 0.0236) 1.0 (0.039)

EM-193

0.20 - 0.35 (0.0079 - 0.0138) 0.5 (0.020)

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)

CRANKSHAFT

AVAILABLE MAIN BEARING Unit: mm (in)

Main journal dia. “Dm” Grade No. 0

54.974 - 54.980 (2.1643 - 2.1646)

Grade No. 1

54.968 - 54.974 (2.1641 - 2.1643)

Grade No. 2

54.962 - 54.968 (2.1639 - 2.1641)

Grade No. 3

54.956 - 54.962 (2.1636 - 2.1639)

Pin journal dia. “Dp” Grade No. 0

47.968 - 47.974 (1.8885 - 1.8887)

Grade No. 1

47.962 - 47.968 (1.8883 - 1.8885)

Grade No. 2

47.956 - 47.962 (1.8880 - 1.8883)

Center distance “r”

SEM021D

42.96 - 43.04 (1.6913 - 1.6945)

Out-of-round (X − Y) Pin journal: Less than 0.0025 (0.0001) Main journal: Less than 0.005 (0.0002)

Standard

Main bearing (Standard) Unit: mm (in)

Taper (A − B) Pin journal: Less than 0.0025 (0.0001) Main journal: Less than 0.005 (0.0002)

Standard

Grade number

Thickness “T”

0

1.977 - 1.980 (0.0778 - 0.0780)

Black (A)

1

1.980 - 1.983 (0.0780 - 0.0781)

Red (B)

2

1.983 - 1.986 (0.0781 - 0.0782)

Green (C)

3

1.986 - 1.989 (0.0782 - 0.0783)

4

1.989 - 1.992 (0.0783 - 0.0784)

Blue (E)

5

1.992 - 1.995 (0.0784 - 0.0785)

Pink (F)

6

1.995 - 1.998 (0.0785 - 0.0787)

White (G)

Runout [TIR] Standard

Less than 0.025 (0.0010)

Limit

Less than 0.05 (0.0020)

Free end play Standard

0.10 - 0.26 (0.0039 - 0.0102)

Limit

0.30 (0.0118)

Identification color (mark)

Width “W”

18.9 - 19.1 (0.744 - 0.752)

Yellow (D)

Main bearing (Undersize) Unit: mm (in) SEM954C

Out-of-round X - Y Taper A-B A

B

Y

X

EM715

EM-194

Undersize

Thickness “T”

Main journal diameter “Dm”

0.25 (0.0098)

2.109 - 2.117 (0.0830 - 0.0833)

Grind so that bearing clearance is the specified value.

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

AVAILABLE CONNECTING ROD BEARING

Bearing clearance Unit: mm (in)

Connecting rod bearing Main bearing clearance

Standard size

Standard

Unit: mm (in) Grade number

Thickness “T”

0

1.500 - 1.503 (0.0591 - 0.0592)

1

1.503 - 1.506 (0.0592 - 0.0593)

2

1.506 - 1.509 (0.0593 - 0.0594)

Width “W”

0.004 - 0.022 (0.0002 - 0.0009)

Limit

Identification color (mark)

0.05 (0.0020)

Connecting rod bearing clearance Standard

Black or Yellow

0.020 - 0.045 (0.0008 - 0.0018)

Limit 16.9 - 17.1 (0.665 - 0.673)

0.065 (0.00256)

Brown or Red Green or Blue

MISCELLANEOUS COMPONENTS Unit: mm (in)

Undersize Unit: mm (in) Undersize

Thickness “T”

0.08 (0.0031)

1.541 - 1.549 (0.0607 - 0.0610)

0.12 (0.0047)

1.561 - 1.569 (0.0615 - 0.0618)

0.25 (0.0098)

1.626 - 1.634 (0.0640 - 0.0643)

Camshaft sprocket runout limit [TIR]

0.25 (0.0098)

Flywheel runout limit [TIR]

0.15 (0.0059)

Drive plate runout limit [TIR]

Crank pin journal diameter “Dp”

Grind so that bearing clearance is the specified value.

EM-195

0.2 (0.008)

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications Cylinder arrangement Displacement

In-line 4 3

cm (cu in)

Bore and stroke

mm (in)

Valve timing

1,974 (120.45) 84.5 × 88.0 (3.329 × 3.465)

Valve arrangement

OHC

Firing order

1-3-4-2

Number of piston rings Compression

2

Oil

1

Number of main bearing

5

Compression ratio

22.2 EM120 Unit: degree a

b

c

d

e

f

248°

232°

14°

38°

12°

56°

Inspection and Adjustment COMPRESSION PRESSURE

CAMSHAFT AND CAMSHAFT BEARING

Unit: kPa (bar, kg/cm2, psi) at 200 rpm Standard

3,138 (31.4, 32, 455)

Limit

2,452 (24.5, 25, 356)

Difference limit between cylinders

490 (4.9, 5, 71)

CYLINDER HEAD Unit: mm (in)

Unit: mm (in) Standard

Max. tolerance

Camshaft journal clearance

0.045 - 0.086 (0.0018 - 0.0034)

0.1 (0.004)

Inner diameter of camshaft bearing

30.000 - 30.021 (1.1811 - 1.1819)

—

Outer diameter of camshaft journal

29.935 - 29.955 (1.1785 - 1.1793)

—

Camshaft runout

Less than 0.02 (0.0008)

0.05 (0.0020)

0.115 - 0.188 (0.0045 - 0.0074)

—

Head surface flatness Camshaft end play Standard Limit Nominal cylinder head height

Less than 0.03 (0.0012) 0.1 (0.004) 137.9 - 138.1 (5.429 - 5.437)

EM671

Cam height “A”

EM-196

Intake

48.70 - 48.75 (1.9173 - 1.9193)

Exhaust

49.15 - 49.20 (1.9350 - 1.9370)

SERVICE DATA AND SPECIFICATIONS (SDS)

CD20T

Inspection and Adjustment (Cont’d)

VALVE

Valve spring Unit: mm (in) Inner Free height

Outer

mm (in) Intake

36.57 (1.4398)

42.25 (1.6634)

Exhaust

41.27 (1.6248)

49.35 (1.9429)

Intake

233.21 (23.78, 52.43) at 22.2 (0.874)

437.69 (44.63, 98.41) at 25.7 (1.012)

Exhaust

233.4 (23.8, 52.5) at 22.2 (0.874)

437.4 (44.6, 98.3) at 25.7 (1.012)

Intake

208.01 (21.21, 46.77) at 22.2 (0.874)

392.28 (40.00, 88.20) at 25.7 (1.012)

Exhaust

208.69 (21.28, 46.92) at 22.2 (0.874)

390.42 (39.81, 87.78) at 25.7 (1.012)

Pressure N (kg, lb) at height

mm (in)

Standard SEM188

Valve head diameter “D” Intake

39.0 - 39.3 (1.535 - 1.547)

Exhaust

32.0 - 32.3 (1.260 - 1.272)

Valve length “L” Intake

99.53 - 99.97 (3.9185 - 3.9358)

Exhaust

99.38 - 99.82 (3.9126 - 3.9299)

Valve stem diameter “d”

Limit

Out-of-square

mm (in)

Intake

6.965 - 6.980 (0.2742 - 0.2748)

Intake

Less than 1.6 (0.063)

Less than 1.8 (0.071)

Exhaust

6.945 - 6.960 (0.2734 - 0.2740)

Exhaust

Less than 1.8 (0.071)

Less than 2.2 (0.087)

Valve seat angle “α”

45°30′

Valve margin “T” limit

0.5 (0.020)

Valve stem end surface grinding limit

0.5 (0.020)

Valve guide Unit: mm (in) Standard

Service

11.023 - 11.034 (0.4340 - 0.4344)

11.223 - 11.234 (0.4418 - 0.4423)

Valve guide Outer diameter Valve guide Inner diameter (Finished size)

7.000 - 7.015 (0.2756 - 0.2762)

Cylinder head valve guide hole diameter

10.985 - 10.996 (0.4325 - 0.4329)

Interference fit of valve guide

0.027 - 0.049 (0.0011 - 0.0019)

11.185 - 11.196 (0.4404 - 0.4408)

Standard

Max. tolerance

Intake

0.020 - 0.050 (0.0008 - 0.0020)

0.10 (0.0039)

Exhaust

0.040 - 0.070 (0.0016 - 0.0028)

0.10 (0.0039)

Stem to guide clearance

Valve deflection limit

EM-197

0.1 (0.004)

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)

Valve seat resurfacing

Unit: mm (in)

VALVE LIFTER Unit: mm (in) Valve lifter outer diameter 34.959 - 34.975 (1.3763 - 1.3770)

Standard Cylinder head valve lifter hole diameter

34.998 - 35.018 (1.3779 - 1.3787)

Clearance 0.023 - 0.059 (0.0009 - 0.0023)

Standard Limit

0.1 (0.004)

AVAILABLE SHIMS Thickness mm (in)

Identification mark

2.20 (0.0866)

220

2.25 (0.0886)

225

2.30 (0.0906)

230

2.35 (0.0925)

235

2.40 (0.0945)

240

2.45 (0.0965)

245

2.50 (0.0984)

250

2.55 (0.1004)

255

2.60 (0.1024)

260

2.65 (0.1043)

265

2.70 (0.1063)

270

2.75 (0.1083)

275

2.80 (0.1102)

280

2.85 (0.1122)

285

2.90 (0.1142)

290

SEM917-B

VALVE CLEARANCE Unit: mm (in) For adjusting Hot Intake Exhaust

0.25 (0.010 0.39 (0.015

-

0.35 0.014) 0.49 0.019)

Cold* (reference data) 0.20 - 0.30 (0.008 - 0.012) 0.33 - 0.43 (0.013 - 0.017)

*: At a temperature of approximately 20°C (68°F)

SEM113FA

EM-198

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

CYLINDER BLOCK Unit: mm (in)

PISTON, PISTON RING AND PISTON PIN Piston Unit: mm (in)

Standard Piston skirt diameter

Grade No. 1

84.460 - 84.470 (3.3252 - 3.3256)

Grade No. 2

84.470 - 84.480 (3.3256 - 3.3260)

Grade No. 3

84.480 - 84.490 (3.3260 - 3.3264)

Grade No. 4

84.490 - 84.500 (3.3264 - 3.3268)

Grade No. 5

84.500 - 84.510 (3.3268 - 3.3272)

0.25 (0.0098)

84.710 - 84.760 (3.3350 - 3.3370)

0.5 (0.020)

84.960 - 85.010 (3.3449 - 3.3468)

Oversize

Measure position (From Top) SEM902-A

Surface flatness

Piston pin hole diameter

Standard

Limit

Less than 0.03 (0.0012)

0.10 (0.0039)

62 (2.44) 27.991 - 27.999 (1.1020 - 1.1023)

Grade No. 1 84.500 - 84.510 (3.3268 - 3.3272)

Piston ring

Grade No. 2

Unit: mm (in)

84.510 - 84.520 (3.3272 - 3.3276) Inner diameter Cylinder bore

Grade No. 3 84.520 - 84.530 (3.3276 - 3.3279)

Side clearance 0.2 (0.008)

Top Standard

Grade No. 4

Limit

84.530 - 84.540 (3.3279 - 3.3283)

Standard

Grade No. 5

Limit

0.050 - 0.085 (0.0020 - 0.0033) 0.10 (0.0039)

Oil

Out-ofround (X − Y)

Less than 0.015 (0.0006)

0.04 (0.0016)

Taper (A − B)

Less than 0.010 (0.0004)

0.04 (0.0016)

0.030 - 0.050 (0.0012 - 0.0020)

—

Standard

0.030 - 0.070 (0.0012 - 0.0028)

End gap Top Standard

Grade No. 0 56.654 - 56.663 (2.2305 - 2.2308) Main journal inner diameter

0.10 (0.0039)

2nd

84.540 - 84.550 (3.3283 - 3.3287)

Piston to cylinder clearance

0.020 - 0.040 (0.0008 - 0.0016)

0.22 - 0.32 (0.0087 - 0.0126)

Bore grade 4, 5

0.12 - 0.22 (0.0047 - 0.0087)

Limit

Grade No. 1 56.663 - 56.672 (2.2308 - 2.2312)

Bore grade 1, 2, 3

1.0 (0.039)

2nd

—

Standard

Grade No. 2

Limit

56.672 - 56.680 (2.2312 - 2.2315)

0.38 - 0.53 (0.0150 - 0.0209) 0.7 (0.028)

Oil Standard Limit

EM-199

0.30 - 0.55 (0.0118 - 0.0217) 0.6 (0.024)

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d)

Piston pin

CRANKSHAFT Unit: mm (in)

Unit: mm (in)

27.994 - 28.000 (1.1021 - 1.1024)

Piston pin outer diameter Interference fit of piston pin to piston

Main journal dia.

Grade No. 0 52.967 - 52.975 (2.0853 - 2.0856) Grade No. 1 52.959 - 52.967 (2.0850 - 2.0853) Grade No. 2 52.951 - 52.959 (2.0847 - 2.0850)

Pin journal dia.

Grade No. 0 49.968 - 49.974 (1.9672 - 1.9675) Grade No. 1 49.961 - 49.968 (1.9670 - 1.9672) Grade No. 2 49.954 - 49.961 (1.9667 - 1.9670)

−0.004 to 0 (−0.0002 to 0)

Piston pin to connecting rod clearance

0.025 - 0.044 (0.0010 - 0.0017)

CONNECTING ROD Unit: mm (in) Bend [per 100 mm (3.94 in)] Standard

Less than 0.025 (0.0010)

Torsion Standard

Less than 0.025 (0.0010) Out-of-round (X − Y) and taper (A − B)

28.025 - 28.038 (1.1033 - 1.1039)

Piston pin bore dia.

Standard

Less than 0.005 (0.0002)

Big end play Runout Limit

0.3 (0.012) Standard

Less than 0.05 (0.0020)

Free end play Standard

0.05 - 0.18 (0.0020 - 0.0071)

Limit

0.3 (0.012)

Width “W” mm (in)

Identification color

AVAILABLE MAIN BEARINGS No. 1, No. 2, No. 4 and No. 5 main bearings Grade number

Thickness “T” mm (in)

0

1.816 - 1.820 (0.0715 - 0.0717)

Yellow

1

1.820 - 1.824 (0.0717 - 0.0718)

Green

2

1.824 - 1.828 (0.0718 - 0.0720)

3

1.828 - 1.832 (0.0720 - 0.0721)

Black

4

1.832 - 1.836 (0.0721 - 0.0723)

Blue

20.0 (0.787) 17.8 (0.701)*

Brown

*: Contacting width

No. 3 main bearings Grade number

Thickness “T” mm (in)

0

1.816 - 1.820 (0.0715 - 0.0717)

Width “W” mm (in)

Yellow

1

1.820 - 1.824 (0.0717 - 0.0718)

Green

2

1.824 - 1.828 (0.0718 - 0.0720)

3

1.828 - 1.832 (0.0720 - 0.0721)

Black

4

1.832 - 1.836 (0.0721 - 0.0723)

Blue

27.95 (1.1004) 21.35 (0.8405)*

*: Contacting width

EM-200

Identification color

Brown

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment (Cont’d)

Main bearing undersize

Bearing clearance Unit: mm (in) Crank journal diameter

STD

52.951 - 52.975 (2.0847 - 2.0856)

0.25 (0.0098) undersize

52.701 - 52.725 (2.0748 - 2.0758)

Unit: mm (in) Main bearing clearance 0.039 - 0.065 (0.0015 - 0.0026)

Standard Connecting rod bearing clearance Standard

0.031 - 0.055 (0.0012 - 0.0022)

Connecting rod bearing undersize Unit: mm (in)

TURBOCHARGER Unit: mm (in)

Crank pin diameter Grade 0 STD

Grade 1 Grade 2

Black

49.968 - 49.974 (1.9672 - 1.9675)

Yellow

49.961 - 49.968 (1.9670 - 1.9672)

Blue

49.954 - 49.961 (1.9667 - 1.9670)

0.08 (0.0031) undersize

49.874 - 49.894* (1.9635 - 1.9643)

0.12 (0.0047) undersize

49.834 - 49.854* (1.9620 - 1.9628)

0.25 (0.0098) undersize

49.704 - 49.724* (1.9568 - 1.9576)

*: Reference value

Rotor shaft Runout [TIR*]

0.056 - 0.127 (0.0022 - 0.0050)

End play

0.013 - 0.097 (0.0005 - 0.0038)

*: Total indicator reading

MISCELLANEOUS COMPONENTS Unit: mm (in) Flywheel Runout [TIR*] *: Total indicator reading

EM-201

Less than 0.15 (0.0059)

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

EM-202

CD20T

ENGINE LUBRICATION & COOLING SYSTEMS SECTION

LC

CONTENTS PRECAUTION..................................................................2 PREPARATION................................................................3 Special Service Tools ..................................................3 QG ENGINE LUBRICATION SYSTEM..................................4 Lubrication Circuit ........................................................4 Oil Pressure Check......................................................5 Oil Pump ......................................................................5 Oil Filter .......................................................................7 ENGINE COOLING SYSTEM..........................................8 Cooling Circuit .............................................................8 System Check..............................................................8 Water Pump ...............................................................10 Thermostat.................................................................11 Radiator .....................................................................13 SR20DE ENGINE LUBRICATION SYSTEM................................15 Lubrication Circuit ......................................................15 Oil Pressure Check....................................................16 Oil Pump ....................................................................17 Oil Filter .....................................................................19 Oil Cooler...................................................................20 ENGINE COOLING SYSTEM........................................21 Cooling Circuit ...........................................................21 System Check............................................................21 Cooling System Inspection ........................................21 Water Pump ...............................................................22 Thermostat.................................................................23 Radiator .....................................................................25 CD20T ENGINE LUBRICATION SYSTEM ................................26 Lubrication Circuit ......................................................26

Oil Pressure Check....................................................27 Oil Pump ....................................................................27 Oil Cooler...................................................................30 ENGINE COOLING SYSTEM........................................31 Cooling Circuit ...........................................................31 System Check............................................................32 Water Pump ...............................................................33 Thermostat.................................................................34 Radiator .....................................................................36

Overheating Cause Analysis .....................................37 QG SERVICE DATA AND SPECIFICATIONS (SDS) ..........39 Oil Pressure Check....................................................39 Oil Pump Inspection ..................................................39 Regulator Valve Inspection........................................39 Thermostat.................................................................39 Radiator .....................................................................39 SR20DE Oil Pressure Check....................................................40 Oil Pump Inspection ..................................................40 Regulator Valve Inspection........................................40 Thermostat.................................................................40 Radiator .....................................................................40 CD20T Oil Pressure Check....................................................41 Oil Pump Inspection ..................................................41 Thermostat.................................................................41 Radiator .....................................................................41

LC

PRECAUTION LIQUID GASKET APPLICATION PROCEDURE 1.

Inner side

2. 쐌

Groove

Bolt hole SEM164

쐌 3. 4. 5.

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) wide for SR engine and 3.5 to 4.5 mm (0.138 to 0.177 in) wide for QG and CD engine (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

Inner side Groove .

AEM080

LC-2

PREPARATION Special Service Tools

Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number Tool name

Engine application

Description SR

CD

QG

X

X

X

X

X

X

X

—

X

—

X

—

X

X

X

X

X

X

Measuring oil pressure

ST25051001* Oil pressure gauge PS1/4x19/in

Maximum measuring range: 2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)

NT558

ST25052000* Hose

PS1/8x28/in PS1/4x19/in

Adapting oil pressure gauge to cylinder block

NT559

Removing oil filter

KV10115801 or KV10115800 Oil filter wrench

15 faces, Inner span: 64.3 mm (2.531 in) (Face to opposite face)

NT362

99545R2500 (KV10106S0) Oil filter wrench

Removing oil filter 15 faces, Inner span: 92.5 mm (3.642 in) (Face to opposite corner) NT631

Pressing the tube of liquid gasket

WS39930000 Tube presser

NT052

Adapting radiator cap tester to radiator filler neck

EG17650301 Radiator cap tester adapter

a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in)

NT564

*:Special tool or commercial equivalent

LC-3

QG

ENGINE LUBRICATION SYSTEM Lubrication Circuit

Lubrication Circuit

NCLC0003

Oil drop

Exhaust camshaft

Intake camshaft

VTC Main gallery

Timing chain guide Chain tensioner

Oil jet Relief valve

Oil filter Oil pump Oil strainer

SEM852F

Oil passage Oil pan

Oil strainer Oil gallery in cylinder block By-pass passage Oil pump

Regulator valve

Oil jet Drain

Oil pressure relief valve

Oil filter

Cylinder head oil gallery

Main oil gallery

Main bearing

Timing chain oil jet

Connecting rod bearing

Timing chain

Valve timing control solenoid (OFF)

Connecting rod

#1 Intake camshaft journal

#1 Exhaust camshaft journal

Exhaust camshaft journal

#1 Intake camshaft

#1 Exhaust camshaft

Exhaust camshaft

Intake camshaft

Valve lifter

Valve lifter

Intake camshaft journal

Chain tensioner

(ON)

Valve timing controller

Piston

SEM938F

LC-4

QG

ENGINE LUBRICATION SYSTEM

Oil Pressure Check

Oil Pressure Check

Oil pressure switch

Front

NCLC0004

WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Put gearshift lever in Neutral “N” position. 1. Check oil level. 2. Remove oil pressure switch.

SEM853F

3. 4. 5.

Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load.

ST25051001

Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

600

More than 98 (0.98, 1.0, 14)

2,000

More than 294 (2.94, 3.0, 43)

6,000

More than 392 (3.92, 4.0, 57)

ST25052000 SLC926-A

쐌 6.

If difference is extreme, check oil passage and oil pump for oil leaks. Install oil pressure switch with sealant.

Oil Pump REMOVAL AND INSTALLATION 쐌 쐌 쐌 1. 2. 3. 4. 5. 6. 7.

NCLC0005

Always replace oil seal with a new one. Refer to EM section (“OIL SEAL REPLACEMENT”). When installing oil pump, apply engine oil to gears. Make sure that O-ring is fitted properly. Drain engine oil. Remove drive belts. Remove oil pan. Refer to EM section (“OIL PAN”). Remove oil strainer. Remove front cover. Refer to EM section (“TIMING CHAIN”). Install front cover. Reinstall parts in reverse order of removal.

LC-5

QG

ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)

DISASSEMBLY AND ASSEMBLY

NCLC0006

SEC. 135⋅150 7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)

7.8 - 12.7 (0.80 - 1.30, 69.4 - 112.8)

: Lubricate with new engine oil. 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

: Use Genuine Liquid Gasket or equivalent. : Do not re-use. : N·m (kg-m; in-lb)

39 - 59 (4.0 - 6.0, 29 - 43)

: N·m (kg-m, ft-lb)

1. 2. 3. 4.

SEM854FA

5. 6. 7.

Oil pump cover Inner gear Outer gear Front cover

Gasket Oil strainer Regulator valve

8. Spring 9. Washer 10. Plug

INSPECTION Feeler gauge

NCLC0007

Using a feeler gauge, check the following clearances. Standard clearance: Unit: mm (in) Body to outer gear radial clearance 1 Inner gear to outer gear tip clearance 2

Front cover SEM855F

0.250 - 0.325 (0.0098 - 0.0128) Below 0.18 (0.0071)

Body to inner gear clearance 3

0.030 - 0.085 (0.0012 - 0.0033)

Body to outer gear axial clearance 4

0.030 - 0.090 (0.0012 - 0.0035)

Inner gear to brazed portion of housing clearance 5

0.045 - 0.091 (0.0018 - 0.0036)

Straightedge

Front cover

Feeler gauge SEM856F

LC-6

QG

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont’d) Inside micrometer

쐌 쐌

If the tip clearance (2) exceeds the limit, replace gear set. If body to gear clearances (1, 3, 4, 5) exceed the limit, replace front cover assembly.

Front cover Micrometer

Inner gear SEM857F

REGULATOR VALVE INSPECTION Spring Regulator valve

NCLC0008

1. 2.

Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or front cover assembly.

Washer Plug

SLC986AA Front cover

4.

Check regulator valve to front cover clearance. Clearance: 6 : 0.052 - 0.088 mm (0.0020 - 0.0035 in) If it exceeds the limit, replace front cover assembly.

Regulator valve

SLC101B

Oil Filter

Oil filter body Relief valve Filtering paper Screw

Body color (gray)

Label (red) Packing

NCLC0010

The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 The new and previous oil filter designs differ from each other and are not interchangeable. 쐌 Use Tool KV10115801 for removing oil filter.

SLC972A

LC-7

QG

ENGINE COOLING SYSTEM Cooling Circuit

Cooling Circuit

Radiator

NCLC0016

Thermostat: CLOSED

Reservoir tank

Thermostat: OPEN Water inlet

Thermostat

Heater

Thermostat housing

Water pump

Cylinder block

EGR valve

Throttle body

Cylinder head

Thermostat housing

Water outlet

SEM939F

System Check

NCLC0017

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.

CHECKING COOLING SYSTEM HOSES Check hoses for the following: 쐌 Improper attachment 쐌 Leaks 쐌 Cracks 쐌 Damage 쐌 Loose connections 쐌 Chafing 쐌 Deterioration

LC-8

NCLC0017S01

QG

ENGINE COOLING SYSTEM

System Check (Cont’d)

CHECKING COOLING SYSTEM FOR LEAKS

NCLC0017S02

To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher pressure than specified may cause radiator damage.

EG17650301

ULC015

CHECKING RADIATOR

NCLC0017S04

Check radiator for mud or clogging. If necessary, clean radiator as follows. 쐌 Be careful not to bend or damage the radiator fins. 쐌 When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically download. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically download. 쐌 Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CHECKING RADIATOR CAP

NCLC0017S03

To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) SLC613-A

Pull the negative pressure valve to open it. Check that it closes completely when released.

SMA967B

LC-9

ENGINE COOLING SYSTEM

QG

Water Pump

Water Pump REMOVAL AND INSTALLATION SEC. 210

NCLC0018

Gasket 17 - 24 (1.7 - 2.4, 12 - 17)

Water pump

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Do not re-use

Water pump pulley

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)

17 - 24 (1.7 - 2.4, 12 - 17) SEM858F

CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, and check for leaks using radiator cap tester.

1.

2. 3. 4. 5.

Drain coolant from radiator and cylinder block. Refer to MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Remove cylinder head front mounting bracket. Remove drive belts and idler pulley. Loosen water pump pulley bolts. Remove water pump pulley.

6. 7. 8.

Remove water pump bolts. Remove water pump with gasket. Reinstall parts in reverse order of removal.

Drain plug

SEM869F

Water pump

SEM859F

LC-10

QG

ENGINE COOLING SYSTEM

Thermostat

INSPECTION 쐌 쐌

NCLC0019

Check body assembly and vane for rust or corrosion. Check for rough operation due to excessive end play.

SEM860F

Thermostat REMOVAL AND INSTALLATION

NCLC0021

17 - 24 (1.7 - 2.4, 12 - 17)

SEC. 210

Thermostat housing Bracket

Gasket

Water outlet 6.0 - 7.7 (0.61 - 0.79, 52.9 - 68.6)

To upper radiator hose Engine front

Washer

Thermostat Water inlet 6.7 - 7.8 (0.68 - 0.80, 59.0 - 69.4)

Do not re-use.

17 - 24 (1.7 - 2.4, 12 - 17) Gum ring

: N·m (kg-m, in-lb) 17 - 24 (1.7 - 2.4, 12 - 17)

: N·m (kg-m, ft-lb)

From lower radiator hose

쐌

Gum ring

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Upper Jiggle valve (top side)

SEM861F

쐌 1. 2. 3.

Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. Use Genuine Liquid Gasket or equivalent. Drain engine coolant. Remove lower radiator hose. Remove water inlet, then take out thermostat.

4.

Install gum ring to thermostat.

Thermostat flange

SEM862F

LC-11

QG

ENGINE COOLING SYSTEM Thermostat (Cont’d) Jiggle valve position

Jiggle valve

Thermostat housing

5. 쐌

Install thermostat with jiggle valve or air bleeder at upper side. After installation, run engine for a few minutes, and check for leaks.

Thermostat SEM863F

INSPECTION 1. 2.

Valve opening temperature Valve lift

3.

NCLC0022

Check for valve seating condition at normal room temperature. It should seat tightly. Check valve opening temperature and valve lift.

mm/°C (in/°F)

°C (°F)

82 (180) More than 9/95 (0.35/203)

Then check if valve closes at 5°C (41°F) below valve opening temperature.

SLC343

LC-12

QG

ENGINE COOLING SYSTEM

Radiator

Radiator COMPONENTS

=NCLC0025

4.0 - 4.5 (0.41 - 0.45, 36 - 39) 4.0 - 4.5 (0.41 - 0.45, 36 - 39)

3.8 - 4.5 (0.39 - 0.45, 34 - 39)

3.25 - 4.25 (0.34 - 0.43, 29 - 37)

: N·m (kg-m, in-lb)

NLC086

1 쑗 2 쑗 3 쑗 4 쑗

Reservoir tank Reservoir hose Radiator cap Mounting bracket

5 쑗 6 쑗 7 쑗 8 쑗

Upper radiator hose Mounting rubber Cooling fan motor Radiator

LC-13

9 쑗 10 쑗 11 쑗

Lower radiator hose Cooling fan Cooling fan motor shield

ENGINE COOLING SYSTEM

QG

Radiator (Cont’d)

Cooling Fan Control System

NCLC0026

Cooling fans are controlled by the ECM. For details, refer to EC section [TROUBLE DIAGNOSIS FOR OVERHEAT (COOLING SYSTEM)].

Refilling Engine Coolant

NCLC0027

For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-30)

LC-14

SR20DE

ENGINE LUBRICATION SYSTEM

Lubrication Circuit

Lubrication Circuit Return

Camshaft

Feed Relief valve

Hydraulic lash adjuster

Oil filter

Oil filter bracket

Oil cooler

Oil pump

Oil pan

Oil strainer

SLC093B

Oil pan

Oil strainer

Oil pump

Regulator valve (Built into oil pump)

Oil filter

Relief valve

Oil cooler

Relief valve (Built into oil filter)

Main gallery

Chain tensioner Timing chain

Main bearing

Connecting rod bearing

Cylinder head oil gallery

Connecting rod Camshaft journal

Hydraulic lash adjuster

Oil gallery Oil passage By-pass passage

Piston and cylinder

To oil pan

NLC043

LC-15

ENGINE LUBRICATION SYSTEM

SR20DE

Oil Pressure Check .

Oil Pressure Check

SR20DE models .

.

Oil pressure switch

WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Oil pressure check should be done in “Neutral position”. 1. Check oil level. 2. Remove oil pressure switch.

Oil cooler .

NLC045

3. 4. 5.

.

SLC717A

Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load. Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

Idle speed

More than 78 (0.78, 0.8, 11)

3,200

314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

LC-16

SR20DE

ENGINE LUBRICATION SYSTEM

Oil Pump

Oil Pump REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8.

Drain engine oil Remove drive belts. Remove cylinder head. (Refer to EM section). Remove oil pan. (Refer to EM section). Remove oil strainer and baffle plate. Remove front cover assembly. Install front cover assembly. Reinstall any parts removed in reverse order of removal

DISASSEMBLY AND ASSEMBLY SEC. 135⋅150 3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3) 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)

Gasket

.

: N·m (kg-m, ft-lb)

16 - 19 (1.6 - 1.9, 12 - 14)

: N·m (kg-m, in-lb) : Apply engine oil.

50 - 70 (5.1 - 7.1, 37 - 51)

NLC050

: Apply liquid gasket. 1 쑗 2 쑗 3 쑗

Oil pump cover Front cover Inner gear

4 쑗 5 쑗 6 쑗

Outer gear Regulator valve Spring

쐌 쐌 쐌

7 쑗 8 쑗 9 쑗

Plug Regulator valve set Oil strainer

Always replace oil seal, gasket and O-ring with new ones. When installing oil pump, apply engine oil to inner and outer gears. Be sure that O-rings are properly fitted.

LC-17

SR20DE

ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)

Feeler gauge

Front cover

Straightedge

Feeler gauge SLC494A

SLC495A

Front cover

Inner gear SLC450A SLC860A

INSPECTION Using a feeler gauge, check the following clearances: Unit: mm (in) 1 쑗 Inner gear to outer gear tip clearance 쑗 2 Body to inner gear clearance 쑗 3 Body to outer gear clearance (axial) 쑗 4

Body to outer gear clearance (radial)

0.114 - 0.200 (0.0045 - 0.0079) Below 0.18 (0.0071) 0.05 - 0.09 (0.0020 - 0.0035) 0.05 - 0.11 (0.0020 - 0.0043)

Inner gear to brazed portion of housing clear- 0.045 - 0.091 (0.0018 - 0.0036) ance 쑗 5

쐌 쐌

If the tip clearance (쑗 2 ) exceeds the limit, replace gear set. If body to gear clearances (쑗 1 , 쑗 3 , 쑗 4 , 쑗 5 ) exceed the limit, replace front cover assembly.

LC-18

SR20DE

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont’d)

REGULATOR VALVE INSPECTION Spring Regulator valve

Washer Cap

1. 2.

Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that regulator valve falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump cover.

SLC986AA

4.

Oil pump cover

Regulator valve

Check regulator valve to oil pump cover clearance. Clearance: 6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in) 쑗 If it exceeds the limit, replace oil pump cover.

SLC451A

Oil Filter

Oil filter body

The oil filter is a small, full-flow cartridge type and is provided with a relief valve. 쐌 The new and existing oil filter designs differ from each other and are not interchangeable. 쐌 Use Tool KV10115801 or KV10115800 for removing oil filter.

Relief valve Filtering paper Thread

Gasket

NLC046

LC-19

SR20DE

ENGINE LUBRICATION SYSTEM Oil Cooler

Oil Cooler SEC. 213 Gasket

Oil cooler

Coolant flow O-ring Oil filter

Oil pressure switch 13 - 17 N·m (1.3 - 1.7 kg-m, 9 - 12 ft-lb) Oil cooler assembly : Do not re-use .

: Locking sealant.

34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)

: N·m (kg-m, ft-lb)

NLC047

REMOVAL AND INSTALLATION 1. 2. 3. 쐌 쐌 쐌

Drain engine oil and coolant. Remove oil cooler. Installation is in reverse order of removal Be careful not to burn yourself as engine oil is hot After installation, run engine for a few minutes and check for oil leaks. Do not spill coolant on drive belts.

INSPECTION 1. 2.

Check oil cooler for cracks. Check oil cooler for clogging by blowing through coolant inlet. If necessary, replace oil cooler assembly.

LC-20

ENGINE COOLING SYSTEM

SR20DE Cooling Circuit

Cooling Circuit

YLC029

System Check WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off.

Cooling System Inspection CHECKING HOSES Check water hoses for proper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) SLC613-A

LC-21

ENGINE COOLING SYSTEM

SR20DE

Cooling System Inspection (Cont’d)

Pull the negative pressure valve to open it. Check that it closes completely when released.

SMA967B

CHECKING COOLING SYSTEM FOR LEAKS Hose adapter

.

To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

SLC546AA

Water Pump Drain plug

REMOVAL AND INSTALLATION 1. 2.

8 - 12 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb) Oil level gauge guide .

SEC. 210

16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)

3. 4. 5.

Drain coolant from radiator. Remove cylinder block drain plug located at left front of cylinder block and drain coolant. Remove front RH wheel and engine side cover. Remove drive belts. Remove front engine mounting.

SLC557AA

6. Remove water pump. CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester.

Liquid gasket

Water pump SLC556AA

7. 쐌

Before installing, remove all traces of liquid gasket from mating surface of water pump using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block.

SLC433A

LC-22

SR20DE

ENGINE COOLING SYSTEM

Water Pump (Cont’d)

8. Liquid gasket 2.0 - 3.0 mm (0.079 - 0.118 in)

쐌 9.

Apply a continuous bead of liquid gasket to mating surface of water pump. Use Genuine Liquid Gasket or equivalent. Install any parts removed in reverse order of removal

SLC434A

INSPECTION 1. 2.

Check body assembly for rust or corrosion. Check for rough operation due to excessive end play.

SLC408C

Thermostat SEC. 210 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5) 6.3 - 8.3 (0.64 - 0.85, 55.8 - 73.5)

Thermostat housing

Air relief plug (if so equipped)

16 - 21 (1.6 - 2.1, 12 - 15)

Thermostat

Water inlet 16 - 21 (1.6 - 2.1, 12 - 15) 16 - 21 (1.6 - 2.1, 12 - 15)

2.0 - 3.0 mm (0.079 - 0.118 in) .

2.0 - 3.0 mm (0.079 - 0.118 in)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Apply liquid gasket

SLC050B

LC-23

SR20DE

ENGINE COOLING SYSTEM Thermostat (Cont’d)

REMOVAL AND INSTALLATION

Upper Jiggle valve

1. 2. 3. 4.

SLC767

쐌 5. 쐌 쐌

Remove lower radiator hose and drain engine coolant. Remove water inlet, then take out thermostat. Before installing, remove all traces of liquid gasket from mating surface of each part using a scraper. Apply a continuous bead of liquid gasket to mating surface of each part. Use Genuine Liquid Gasket or equivalent. Install thermostat with jiggle valve or air bleeder facing upward. After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant.

INSPECTION 1. 2.

Check valve seating condition at ordinary temperatures. It should seat tightly. Check valve opening temperature and valve lift.

Valve opening temperature Valve lift

3. SLC343

°C(°F)

mm/°C (in/°F)

82 (180) More than 9/95 (0.35/203)

Then check if valve closes at 5°C (41°F) below valve opening temperature.

LC-24

SR20DE

ENGINE COOLING SYSTEM

Radiator

Radiator SEC. 214 3.8 - 4.5 (0.39 - 0.46, 33.9 - 39.9)

3.7 - 5.0 (0.38 - 0.51, 32.7 - 44.3)

쑗 2

4 쑗

3 쑗

10 쑗

1 쑗

5 쑗

11 쑗

10 쑗 8 쑗

4.0 - 4.5 (0.41 - 0.46, 35.4 - 39.8) 6 쑗

9 쑗

1 쑗 2 쑗 3 쑗 4 쑗

Reservoir tank Reservoir tank hose Radiator cap Mounting bracket

12 쑗

3.25 - 4.25 (0.33 - 0.43, 28.8 - 37.6)

5 쑗 6 쑗 7 쑗 8 쑗

N·m (kg-m, in-lb)

11 쑗

7 쑗

7 쑗

Upper hose Mounting rubber Oil cooler hose (A/T models) Radiator

NLC090

9 쑗 10 쑗 11 쑗 12 쑗

Lower hose Cooling fan Cooling fan motor Cooling fan motor shield

Cooling fan control system 쐌

Cooling fans are controlled by the ECM. For details, refer to EC-section (“COOLING SYSTEM”, “Diagnostic Procedure”, EC-SR-284).

Refilling engine coolant 쐌

For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-41).

LC-25

ENGINE LUBRICATION SYSTEM

CD20T

Lubrication Circuit

Lubrication Circuit

: Oil gallery in cylinder block : Oil passage : By-pass passage

Oil cooler

Oil filter

Oil pump

Relief valve

Relief valve Regulator valve

Cylinder head oil gallery Oil strainer

Turbocharger

Main bearing

Crankshaft

Camshaft bracket Hydraulic valve lifter

Connecting rod bearing

Camshaft journal Oil feed hose

Connecting rod Vacuum pump

Cam lobe

Piston and cylinder wall Oil return hose Oil pan SLC083B

LC-26

CD20T

ENGINE LUBRICATION SYSTEM

Oil Pressure Check

Oil Pressure Check

Oil filter Oil pressure switch

WARNING: 쐌 Be careful not to burn yourself, as the engine and oil may be hot. 쐌 Oil pressure check should be done in “Neutral” gear position. 1. Check oil level. 2. Remove oil pressure switch.

SLC461

3. 4. 5.

Install pressure gauge. Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load.

ST2051001

Engine rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

Idle speed

More than 59 (0.59, 0.6, 9)

2,000

294 (2.9, 3, 43)

ST25052000 SLC926-A

If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.

Oil Pump REMOVAL AND INSTALLATION

Rear engine gusset

1. 2. 3.

Drain engine coolant and engine oil. Remove upper radiator hose, drive belts, crank pulley, timing belt covers and timing belt. (Refer to EM section). Remove exhaust front tube, timing belt pulley and rear engine gusset (bar type), then remove oil pan. (Refer to EM section).

SLC462A

9.2 - 10.8 N·m (0.94 - 1.10 kg-m, 81.4 - 95.6 in-lb)

4. 5. 6.

Crankshaft position sensor (TDC)

쐌 쐌 쐌 쐌 12 - 16 N·m (1.2 - 1.6 kg-m, 9 - 12 ft-lb)

Remove crankshaft position sensor (TDC). Remove oil pump assembly with oil strainer. Reinstall any part removed. Refill engine oil and engine coolant. Apply liquid gasket to oil pump. Apply liquid gasket to oil pan. Apply liquid gasket to both ends of oil pan oil seals. Install oil pan, fitting oil seals in the correct position.

SLC087B

LC-27

CD20T

ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)

DISASSEMBLY AND ASSEMBLY SEC. 150

6 - 8 (0.6 - 0.8, 52 - 69) Cover

Oil pump body

Regulator valve

Spring

.

Inner gear

Shim

39 - 69 (4.0 - 7.0, 29 - 51) Gasket

Plug

N·m (kg-m, ft-lb)

Outer gear

N·m (kg-m, in-lb) 16 - 19 (1.6 - 1.9, 12 - 14) :

2.5 ± 0.5 (0.098 ± 0.020) dia.

Unit: mm (in)

Bolt hole

Apply engine oil

SLC097B

쐌

When installing oil pump, apply engine oil to inner and outer gears.

쐌

Apply liquid gasket when installing oil pump onto engine.

2.5 ± 0.5 (0.098 ± 0.020) dia. SLC566A

LC-28

CD20T

ENGINE LUBRICATION SYSTEM

Oil Pump (Cont’d)

INSPECTION Using a feeler gauge, check the following clearances. Unit: mm (in) Body to outer gear clearance

1 쑗

2 쑗 Housing to inner gear clearance 쑗 3 Housing to outer gear clearance 쑗 4 Inner gear to housing clearance 쑗 5

Outer gear to inner gear clearance

SLC560A

0.114 - 0.200 (0.0045 - 0.0079) Less than 0.18 (0.0071) 0.05 - 0.09 (0.0020 - 0.0035) 0.05 - 0.11 (0.0020 - 0.0043) 0.045 - 0.091 (0.0018 - 0.0036)

If it exceeds the limit, replace gear set or entire oil pump assembly.

SLC561C

SLC567A

SLC568A

REGULATOR VALVE INSPECTION Spring Regulator valve

1. 2.

Visually inspect components for wear and damage. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil. Check that it falls freely into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.

Plug Shim

SLC049B

LC-29

CD20T

ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d)

OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve (indicated by arrow) for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with a suitable tool. Install a new valve by tapping it into place.

SLC446

Oil Cooler SEC. 150⋅213 34 - 44 (3.5 - 4.5, 25 - 33)

.

6 쑗

Front

16 - 21 (1.6 - 2.1, 12 - 15)

Do not re-use

16 - 21 (1.6 - 2.1, 12 - 15)

N·m (kg-m, ft-lb)

1 쑗 2 쑗

SLC084B

3 쑗 4 쑗

Oil cooler Connector

O-ring Oil filter bracket

5 쑗 6 쑗

Gasket Gasket

INSPECTION 1. 2.

Check oil cooler element and housing for cracks. Check coolant inlet of oil cooler for clogging by blowing through it. Replace it if necessary.

Oil cooler

SLC465A

LC-30

CD20T

ENGINE COOLING SYSTEM

Cooling Circuit

Cooling Circuit

Bottom by-pass

To radiator

Oil cooler

From turbocharger

Thermostat

Radiator cap

Reservoir tank

Radiator

Water inlet

Thermostat

Water pump Heater unit

Cylinder block

Oil cooler

Turbocharger Cylinder head

Water outlet : By-pass passage SLC085B

LC-31

ENGINE COOLING SYSTEM

CD20T

System Check

System Check WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap and carefully loosen it a quarter turn to release built-up pressure. Then remove the cap completely.

CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2, 14 - 17 psi) Limit 59 - 118 kPa (0.59 - 1.18 bar, 0.6 - 1.2 kg/cm2, 8.6 - 17.1 psi) SLC613-A

Pull the negative pressure valve to open it. Check that it closes completely when released.

SMA967B

CHECKING COOLING SYSTEM FOR LEAKS To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage. SLC422A

LC-32

ENGINE COOLING SYSTEM

CD20T Water Pump

Water Pump REMOVAL AND INSTALLATION . .

Radiator lower . hose

Radiator

.

NLC040

Drain plug (cylinder block)

CAUTION: 쐌 When removing water pump assembly, be careful not to get coolant on drive belt. 쐌 Water pump cannot be disassembled and should be replaced as a unit. 쐌 After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. 1. Remove radiator lower hose from radiator and drain engine coolant. 2. Drain engine coolant from cylinder block. 3. Remove upper radiator hose, timing belt covers, front engine mounting bracket and timing belt. (Refer to EM section). 4. Remove timing belt tensioner and idler and timing belt lower back cover.

NLC041

5.

Remove water pump.

쐌

When installing water pump, replace the gasket with a new one.

Water pump

.

SLC562AA

22 - 25 N·m (2.2 - 2.6 kg-m, 16 - 19 ft-lb) SLC086B

INSPECTION 쐌 쐌

Check body assembly for rust or corrosion. Check for rough operation due to excessive end play.

SLC760

LC-33

CD20T

ENGINE COOLING SYSTEM Thermostat

Thermostat REMOVAL AND INSTALLATION SEC. 210-211

Water outlet 16 - 21 (1.6 - 2.1, 12 - 15)

From oil cooler 16 - 21 (1.6 - 2.1, 12 - 15)

From heater unit Up

Thermostat Thermostat housing Water inlet 16 - 21 (1.6 - 2.1, 12 - 15)

2.5±0.5 (0.098±0.020) dia.

2.5 (0.098) 3.5 (0.138) Bolt hole

Unit: mm (in) : N·m (kg-m, ft-lb)

Bolt hole 2.5±0.5 (0.098±0.020) dia. 2.5±0.5 (0.098±0.020) dia.

2.5±0.5 (0.098±0.020) dia. 2.5±0.5 (0.098±0.020) dia. SLC564AA

1. 2. 3. 4. 5.

6. 쐌

Upper Jiggle valve

Drain engine coolant. Remove lower radiator hose. Remove water inlet, then take out thermostat. Before installing thermostat, remove all traces of liquid gasket from mating surface of each part using a scraper. Apply liquid gasket to water outlet, thermostat housing and water inlet.

Install thermostat with jiggle valve uppermost. After installation, run engine for a few minutes, and check for leaks.

Air bleeder

SLC097

LC-34

CD20T

ENGINE COOLING SYSTEM

Thermostat (Cont’d)

INSPECTION 1. 2.

Check valve seating condition at ordinary temperatures. It should seat tightly. Check valve opening temperature and valve lift.

Valve opening temperature Valve lift

3. SLC343

°C (°F) 82 (180) mm/°C (in/°F) More than 10/95 (0.39/203)

Then check if valve closes at 5°C (41°F) below valve opening temperature.

LC-35

CD20T

ENGINE COOLING SYSTEM Radiator

Radiator

4.0 - 4.5 (0.41 - 0.45, 36 - 39) 4.0 - 4.5 (0.41 - 0.45, 36 - 39)

3.8 - 4.5 (0.39 - 0.45, 34 - 39)

3.25 - 4.25 (0.33 - 0.43, 28.8 - 37.6) : N·m (kg-m, in-lb) NLC089

1 쑗 2 쑗 3 쑗 4 쑗

Reservoir tank Reservoir tank hose Radiator cap Mounting bracket

5 쑗 6 쑗 7 쑗 8 쑗

Upper radiator hose Mounting rubber Radiator Lower radiator hose

9 쑗 10 쑗 11 쑗

Cooling fan Cooling fan motor Cooling fan motor shield

Cooling fan control system 쐌

Cooling fans are controlled by the ECM. For details, refer to EC section (“COOLING FAN”, “Diagnostic Procedure”, EC-CD90).

Refilling engine coolant 쐌

For details on refilling engine coolant, refer to MA section (“ENGINE MAINTENANCE”, “Changing Engine Coolant”, MA-52).

LC-36

ENGINE COOLING SYSTEM Overheating Cause Analysis

Overheating Cause Analysis Symptom

Check items

Water pump malfunction

Worn or loose drive belt

Thermostat stuck closed Poor heat transfer

NCLC0028

— Dust contamination or paper clogging

Damaged fins

—

Mechanical damage Clogged radiator cooling tube

Excess foreign material (rust, dirt, sand, etc.)

Cooling fan does not operate Reduced air flow

High resistance to fan rotation

—

—

—

—

—

—

—

—

—

—

—

Damaged fan blades Damaged radiator shroud Improper coolant mixture Cooling sys- ratio tem parts malfunction Poor coolant quality

Loose clamp Cooling hose Cracked hose Water pump

Poor sealing Loose

Radiator cap Poor sealing

Coolant leaks

O-ring for damage, deterioration or improper fitting

Insufficient coolant Radiator

Cracked radiator tank Cracked radiator core

Reservoir tank

Cracked reservoir tank Cylinder head deterioration

Overflowing reservoir tank

LC-37

Exhaust gas leaks into cooling system

Cylinder head gasket deterioration

ENGINE COOLING SYSTEM Overheating Cause Analysis (Cont’d) Symptom

Check items High engine rpm under no load Abusive driving

Driving in low gear for extended time Driving at extremely high speed

—

Overload on engine

Powertrain system malfunction Installed improper size wheels and tires

Except cooling system parts malfunction

—

Dragging brakes Improper ignition timing Blocked bumper

— Installed car brassiere

Blocked radiator grille Blocked or restricted air flow Blocked radiator

Mud contamination or paper clogging —

Blocked condenser — Installed large fog lamp

LC-38

—

QG

SERVICE DATA AND SPECIFICATIONS (SDS)

Oil Pressure Check

Oil Pressure Check

NCL0011

Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

600

More than 98 (0.98, 1.0, 14)

2,000

More than 294 (2.94, 3.0, 43)

6,000

More than 392 (3.92, 4.0, 57)

Oil Pump Inspection

NCLC0013

Unit: mm (in) Body to outer gear radial clearance

0.250 - 0.325 (0.0098 - 0.0128)

Inner gear to outer gear tip clearance

Below 0.18 (0.0071)

Body to inner gear clearance

0.030 - 0.085 (0.0012 - 0.0033)

Body to outer gear axial clearance

0.030 - 0.090 (0.0012 - 0.0035)

Inner gear to brazed portion of housing clearance

0.045 - 0.091 (0.0018 - 0.0036)

Regulator Valve Inspection

NCLC0012

Unit: mm (in) Regulator valve to oil pump cover clearance

0.052 - 0.088 (0.0020 - 0.0035)

Thermostat Valve opening temperature Valve lift

°C (°F)

NCLC0029

82 (180)

mm/°C (in/°F)

More than 9/95 (0.35/203)

Radiator

NCLC0030

Unit: kPa (bar, kg/cm2, psi) Standard

78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Limit

59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)

Cap relief pressure Leakage test pressure

157 (1.57, 1.6, 23)

LC-39

SR20DE

SERVICE DATA AND SPECIFICATIONS (SDS) Oil Pressure Check

Oil Pressure Check Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

Idle speed

More than 78 (0.78, 0.8, 11)

3,200

314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)

Oil Pump Inspection Unit: mm (in) Body to outer gear clearance (radial)

0.114 - 0.200 (0.0045 - 0.0079)

Inner gear to outer gear tip clearance

Below 0.18 (0.0020 - 0.0071)

Body to inner gear clearance

0.05 - 0.09 (0.0020 - 0.0035)

Body to outer gear clearance (axial)

0.05 - 0.11 (0.0020 - 0.0043)

Inner gear to brazed portion of housing clearance

0.045 - 0.091 (0.0018 - 0.0036)

Regulator Valve Inspection Unit: mm (in) Regulator valve to oil pump cover clearance

0.040 - 0.097 (0.0016 - 0.0038)

Thermostat Valve opening temperature Valve lift

°C (°F)

82 (180)

mm/°C (in/°F)

More than 9/95 (0.35/203)

Radiator Unit: kPa (bar, kg/cm2, psi) Standard

78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Limit

59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)

Cap relief pressure Leakage test pressure

157 (1.57, 1.6, 23)

LC-40

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS)

Oil Pressure Check

Oil Pressure Check Engine speed rpm

Approximate discharge pressure kPa (bar, kg/cm2, psi)

Idle speed

More than 59 (0.59, 0.6, 9)

2,000

294 (2.9, 3, 43)

Oil Pump Inspection Unit: mm (in) Body to outer gear clearance (radial)

0.114 - 0.200 (0.0045 - 0.0079)

Outer gear to inner gear clearance

Less than 0.18 (0.0071)

Housing to inner gear clearance

0.05 - 0.09 (0.0020 - 0.0035)

Housing to outer gear clearance (axial)

0.05 - 0.11 (0.0020 - 0.0043)

Inner gear to housing clearance

0.045 - 0.091 (0.0018 - 0.0036)

Thermostat Valve opening temperature Valve lift

°C (°F)

82 (180)

mm/°C (in/°F)

More than 10/95 (0.39/203)

Radiator Unit: kPa (bar, kg/cm2, psi) Standard

98 - 118 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)

Limit

59 - 118 (0.59 - 1.18, 0.6 - 1.2, 8.6 - 17.1)

Cap relief pressure Leakage test pressure

157 (1.57, 1.6, 23)

LC-41

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

LC-42

CD20T

ENGINE CONTROL SYSTEM SECTION

EC EC

CONTENTS QG16I18DE TROUBLE DIAGNOSIS - INDEX ....................................6 Alphabetical & P No. Index for DTC ...........................6 PRECAUTIONS ...............................................................9 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............9 Precautions for On Board Diagnostic (OBD) System of Engine ........................................................9 Engine Fuel & Emission Control System ..................10 Precautions ................................................................11 Wiring Diagrams and Trouble Diagnosis...................12 PREPARATION..............................................................13 Special Service Tools ................................................13 Commercial Service Tool...........................................13 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................14 Engine Control Component Parts Location...............14 Circuit Diagram ..........................................................17 System Diagram ........................................................18 Vacuum Hose Drawing ..............................................19 System Chart .............................................................20 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................21 Multiport Fuel Injection (MFI) System .......................21 Electronic Ignition (EI) System ..................................23 Air Conditioning Cut Control......................................24 Fuel Cut Control (at no load & high engine speed) ........................................................................25 Evaporative Emission System ...................................25 Positive Crankcase Ventilation ..................................28 BASIC SERVICE PROCEDURE ...................................29 Fuel Pressure Release ..............................................29 Fuel Pressure Check .................................................29 Fuel Pressure Regulator Check ................................30 Injector .......................................................................30 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................32

Idle Air Volume Learning ...........................................33 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................36 Introduction ................................................................36 Two Trip Detection Logic ...........................................36 Emission-related Diagnostic Information ...................37 Malfunction Indicator (MI) ..........................................45 OBD System Operation Chart ...................................50 CONSULT-II ...............................................................55 Generic Scan Tool (GST) ..........................................66 TROUBLE DIAGNOSIS - INTRODUCTION..................68 Introduction ................................................................68 Work Flow..................................................................70 TROUBLE DIAGNOSIS - BASIC INSPECTION...........72 Basic Inspection.........................................................72 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................80 DTC Inspection Priority Chart....................................80 Fail-safe Chart ...........................................................81 Symptom Matrix Chart...............................................82 CONSULT-II Reference Value in Data Monitor Mode ..........................................................................86 Major Sensor Reference Graph in Data Monitor Mode ..........................................................................88 ECM Terminals and Reference Value .......................91 TROUBLE DIAGNOSIS - SPECIFICATION VALUE ....98 Description .................................................................98 Testing Condition .......................................................98 Inspection Procedure.................................................98 Diagnostic Procedure ................................................99 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................102 Description ...............................................................102 Diagnostic Procedure ..............................................102 TROUBLE DIAGNOSIS FOR POWER SUPPLY........103 Main Power Supply and Ground Circuit..................103

CONTENTS DTC P0100 MASS AIR FLOW SENSOR (MAFS)......110 Component Description ...........................................110 CONSULT-II Reference Value in Data Monitor Mode ........................................................................110 ECM Terminals and Reference Value .....................110 On Board Diagnosis Logic.......................................110 DTC Confirmation Procedure .................................. 111 Wiring Diagram ........................................................112 Diagnostic Procedure ..............................................113 Component Inspection.............................................115 DTC P0110 INTAKE AIR TEMPERATURE SENSOR ......................................................................116 Component Description ...........................................116 On Board Diagnosis Logic.......................................116 DTC Confirmation Procedure ..................................116 Wiring Diagram ........................................................117 Diagnostic Procedure ..............................................118 Component Inspection.............................................119 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT) .......................................120 Component Description ...........................................120 CONSULT-II Reference Value in Data Monitor Mode ........................................................................120 On Board Diagnosis Logic.......................................120 DTC Confirmation Procedure ..................................121 Wiring Diagram ........................................................122 Diagnostic Procedure ..............................................123 Component Inspection.............................................124 DTC P0120 THROTTLE POSITION SENSOR ...........125 Component Description ...........................................125 CONSULT-II Reference Value in Data Monitor Mode ........................................................................125 ECM Terminals and Reference Value .....................126 On Board Diagnosis Logic.......................................126 DTC Confirmation Procedure ..................................126 Wiring Diagram ........................................................128 Diagnostic Procedure ..............................................129 Component Inspection.............................................131 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT).....................................................132 Component Description ...........................................132 CONSULT-II Reference Value in Data Monitor Mode ........................................................................132 ECM Terminals and Reference Value .....................132 On Board Diagnosis Logic.......................................133 DTC Confirmation Procedure ..................................133 Overall Function Check ...........................................134 Wiring Diagram ........................................................135 Diagnostic Procedure ..............................................136 Component Inspection.............................................137

(Cont’d)

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING) .....................139 Component Description ...........................................139 CONSULT-II Reference Value in Data Monitor Mode ........................................................................139 ECM Terminals and Reference Value .....................139 On Board Diagnosis Logic.......................................140 DTC Confirmation Procedure ..................................140 Overall Function Check ...........................................141 Diagnostic Procedure ..............................................141 Component Inspection.............................................143 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING) ......................145 Component Description ...........................................145 CONSULT-II Reference Value in Data Monitor Mode ........................................................................145 ECM Terminals and Reference Value .....................145 On Board Diagnosis Logic.......................................146 DTC Confirmation Procedure ..................................146 Overall Function Check ...........................................147 Diagnostic Procedure ..............................................147 Component Inspection.............................................149 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING).......................151 Component Description ...........................................151 CONSULT-II Reference Value in Data Monitor Mode ........................................................................151 ECM Terminals and Reference Value .....................151 On Board Diagnosis Logic.......................................152 DTC Confirmation Procedure ..................................152 Overall Function Check ...........................................153 Wiring Diagram ........................................................154 Diagnostic Procedure ..............................................155 Component Inspection.............................................158 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)........................................160 Component Description ...........................................160 CONSULT-II Reference Value in Data Monitor Mode ........................................................................160 ECM Terminals and Reference Value .....................160 On Board Diagnosis Logic.......................................161 DTC Confirmation Procedure ..................................161 Wiring Diagram ........................................................162 Diagnostic Procedure ..............................................163 Component Inspection.............................................164 DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER.......................................................166 Description ...............................................................166 CONSULT-II Reference Value in Data Monitor Mode ........................................................................166 ECM Terminals and Reference Value .....................166 On Board Diagnosis Logic.......................................166

EC-2

CONTENTS DTC Confirmation Procedure ..................................167 Wiring Diagram ........................................................168 Diagnostic Procedure ..............................................169 Component Inspection.............................................170 DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)...................171 Component Description ...........................................171 CONSULT-II Reference Value in Data Monitor Mode ........................................................................171 ECM Terminals and Reference Value .....................171 On Board Diagnosis Logic.......................................171 DTC Confirmation Procedure ..................................172 Overall Function Check ...........................................173 Wiring Diagram ........................................................174 Diagnostic Procedure ..............................................175 Component Inspection.............................................178 DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING) .................180 Component Description ...........................................180 CONSULT-II Reference Value in Data Monitor Mode ........................................................................180 ECM Terminals and Reference Value .....................180 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................181 Overall Function Check ...........................................182 Wiring Diagram ........................................................183 Diagnostic Procedure ..............................................184 Component Inspection.............................................186 DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING).........................188 Component Description ...........................................188 CONSULT-II Reference Value in Data Monitor Mode ........................................................................188 ECM Terminals and Reference Value .....................188 On Board Diagnosis Logic.......................................188 DTC Confirmation Procedure ..................................189 Overall Function Check ...........................................190 Wiring Diagram ........................................................191 Diagnostic Procedure ..............................................192 Component Inspection.............................................195 DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE) ..........................................197 Component Description ...........................................197 CONSULT-II Reference Value in Data Monitor Mode ........................................................................197 ECM Terminals and Reference Value .....................197 On Board Diagnosis Logic.......................................197 DTC Confirmation Procedure ..................................198 Overall Function Check ...........................................198 Wiring Diagram ........................................................199 Diagnostic Procedure ..............................................200 Component Inspection.............................................201

(Cont’d)

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR) .........................................................203 Description ...............................................................203 CONSULT-II Reference Value in Data Monitor Mode ........................................................................203 ECM Terminals and Reference Value .....................203 On Board Diagnosis Logic.......................................204 DTC Confirmation Procedure ..................................204 Wiring Diagram ........................................................205 Diagnostic Procedure ..............................................206 Component Inspection.............................................207 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE) ............................................208 On Board Diagnosis Logic.......................................208 DTC Confirmation Procedure ..................................208 Wiring Diagram ........................................................210 Diagnostic Procedure ..............................................211 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE) .............................................215 On Board Diagnosis Logic.......................................215 DTC Confirmation Procedure ..................................215 Wiring Diagram ........................................................217 Diagnostic Procedure ..............................................218 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................222 On Board Diagnosis Logic.......................................222 DTC Confirmation Procedure ..................................222 Diagnostic Procedure ..............................................223 DTC P0325 KNOCK SENSOR (KS) ...........................228 Component Description ...........................................228 ECM Terminals and Reference Value .....................228 On Board Diagnosis Logic.......................................228 DTC Confirmation Procedure ..................................228 Wiring Diagram ........................................................229 Diagnostic Procedure ..............................................230 Component Inspection.............................................231 DTC P0335 CRANKSHAFT POSITION SENSOR (POS)............................................................................232 Component Description ...........................................232 ECM Terminals and Reference Value .....................232 On Board Diagnosis Logic.......................................233 DTC Confirmation Procedure ..................................233 Wiring Diagram ........................................................234 Diagnostic Procedure ..............................................235 Component Inspection.............................................237 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE).........................................................238 Component Description ...........................................238 ECM Terminals and Reference Value .....................238 On Board Diagnosis Logic.......................................238 DTC Confirmation Procedure ..................................239 Wiring Diagram ........................................................240

EC-3

CONTENTS Diagnostic Procedure ..............................................241 Component Inspection.............................................243 DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED)..................................................................244 Description ...............................................................244 CONSULT-II Reference Value in Data Monitor Mode ........................................................................245 ECM Terminals and Reference Value .....................245 On Board Diagnosis Logic.......................................245 DTC Confirmation Procedure ..................................246 Wiring Diagram ........................................................248 Diagnostic Procedure ..............................................249 Component Inspection.............................................251 DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) (IF SO EQUIPPED)....................................252 Description ...............................................................252 CONSULT-II Reference Value in Data Monitor Mode ........................................................................253 ECM Terminals and Reference Value .....................253 On Board Diagnosis Logic.......................................253 DTC Confirmation Procedure ..................................253 Wiring Diagram ........................................................255 Diagnostic Procedure ..............................................256 Component Inspection.............................................257 DTC P0420 THREE WAY CATALYST FUNCTION ...258 On Board Diagnosis Logic.......................................258 DTC Confirmation Procedure ..................................258 Overall Function Check ...........................................259 Diagnostic Procedure ..............................................259 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT) .................262 Description ...............................................................262 CONSULT-II Reference Value in Data Monitor Mode ........................................................................262 ECM Terminals and Reference Value .....................263 On Board Diagnosis Logic.......................................263 DTC Confirmation Procedure ..................................263 Wiring Diagram ........................................................264 Diagnostic Procedure ..............................................265 Component Inspection.............................................266 DTC P0500 VEHICLE SPEED SENSOR (VSS) .........267 Component Description ...........................................267 ECM Terminals and Reference Value .....................267 On Board Diagnosis Logic.......................................267 DTC Confirmation Procedure ..................................267 Wiring Diagram ........................................................269 Diagnostic Procedure ..............................................271 DTC P0505 IDLE AIR CONTROL VALVE (IACV) AUXILIARY AIR CONTROL (AAC) VALVE ................274 Description ...............................................................274 CONSULT-II Reference Value in Data Monitor Mode ........................................................................275

(Cont’d)

ECM Terminals and Reference Value .....................275 On Board Diagnosis Logic.......................................275 DTC Confirmation Procedure ..................................275 Wiring Diagram ........................................................276 Diagnostic Procedure ..............................................277 Component Inspection.............................................281 DTC P0605 ECM .........................................................282 Component Description ...........................................282 On Board Diagnosis Logic.......................................282 DTC Confirmation Procedure ..................................282 Diagnostic Procedure ..............................................282 DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE ......................................................284 Component Description ...........................................284 Operation .................................................................284 CONSULT-II Reference Value in Data Monitor Mode ........................................................................284 ECM Terminals and Reference Value .....................284 On Board Diagnosis Logic.......................................284 DTC Confirmation Procedure ..................................285 Wiring Diagram ........................................................286 Diagnostic Procedure ..............................................287 Component Inspection.............................................288 DTC P1217 OVERHEAT (COOLING SYSTEM) .........289 System Description..................................................289 CONSULT-II Reference Value in Data Monitor Mode ........................................................................289 ECM Terminals and Reference Value .....................290 On Board Diagnosis Logic.......................................290 Overall Function Check ...........................................291 Wiring Diagram ........................................................292 Diagnostic Procedure ..............................................294 Main 12 Causes of Overheating..............................298 Component Inspection.............................................299 DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED) ...........................................................300 Component Description ...........................................300 On Board Diagnosis Logic.......................................300 DTC Confirmation Procedure ..................................300 Wiring Diagram ........................................................302 Diagnostic Procedure ..............................................303 Component Inspection.............................................304 DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED)..................................................................305 Description ...............................................................305 CONSULT-II Reference Value in Data Monitor Mode ........................................................................306 ECM Terminals and Reference Value .....................306 On Board Diagnosis Logic.......................................306 DTC Confirmation Procedure ..................................307 Wiring Diagram ........................................................309 Diagnostic Procedure ..............................................310

EC-4

CONTENTS Component Inspection.............................................311 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH .......................................................................313 Component Description ...........................................313 CONSULT-II Reference Value in Data Monitor Mode ........................................................................313 ECM Terminals and Reference Value .....................313 On Board Diagnosis Logic.......................................313 DTC Confirmation Procedure ..................................313 Overall Function Check ...........................................314 Wiring Diagram ........................................................315 Diagnostic Procedure For M/T Models....................316 INJECTOR ...................................................................318 Component Description ...........................................318 CONSULT-II Reference Value in Data Monitor Mode ........................................................................318 ECM Terminals and Reference Value .....................318 Wiring Diagram ........................................................319 Diagnostic Procedure ..............................................320 Component Inspection.............................................322 IGNITION SIGNAL.......................................................323 Component Description ...........................................323 CONSULT-II Reference Value in Data Monitor Mode ........................................................................323 ECM Terminals and Reference Value .....................323 Wiring Diagram ........................................................324 Diagnostic Procedure ..............................................326 Component Inspection.............................................331 START SIGNAL ...........................................................332 CONSULT-II Reference Value in Data Monitor Mode ........................................................................332 ECM Terminals and Reference Value .....................332 Wiring Diagram ........................................................333 Diagnostic Procedure ..............................................334 FUEL PUMP.................................................................336 System Description..................................................336 Component Description ...........................................336 CONSULT-II Reference Value in Data Monitor Mode ........................................................................336 ECM Terminals and Reference Value .....................337 Wiring Diagram ........................................................338 Diagnostic Procedure ..............................................339

(Cont’d)

Component Inspection.............................................341 POWER STEERING OIL PRESSURE SWITCH.........342 Component Description ...........................................342 CONSULT-II Reference Value in Data Monitor Mode ........................................................................342 ECM Terminals and Reference Value .....................342 Wiring Diagram ........................................................343 Diagnostic Procedure ..............................................344 Component Inspection.............................................346 REFRIGERANT PRESSURE SENSOR ......................347 Description ...............................................................347 ECM Terminals and Reference Value .....................347 Wiring Diagram ........................................................348 Diagnostic Procedure ..............................................349 ELECTRICAL LOAD SIGNAL.....................................351 CONSULT-II Reference Value in Data Monitor Mode ........................................................................351 ECM Terminals and Reference Value .....................351 Wiring Diagram ........................................................352 MI & DATA LINK CONNECTORS...............................354 Wiring Diagram ........................................................354

SERVICE DATA AND SPECIFICATIONS (SDS) ........355 Fuel Pressure Regulator..........................................355 Idle Speed and Ignition Timing................................355 Mass Air Flow Sensor..............................................355 Intake Air Temperature Sensor................................355 Engine Coolant Temperature Sensor ......................355 Throttle Position Sensor ..........................................355 Heated Oxygen Sensor 1 Heater (Front) ................355 Heated Oxygen Sensor 2 Heater (Rear).................355 Crankshaft Position Sensor (POS)..........................356 Camshaft Position Sensor (PHASE) .......................356 EGR Volume Control Valve (If so equipped)...........356 EGR Temperature Sensor (If so equipped).............356 EVAP Canister Purge Volume Control Valve ..........356 IACV-AAC Valve ......................................................356 Injector .....................................................................356 Ignition Coil with Power Transistor ..........................357 Fuel Pump ...............................................................357

EC-5

QG16I18DE

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NCEC0001

ALPHABETICAL INDEX FOR DTC

NCEC0001S01

DTC*5 Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

Unable to access ECM

—

—

EC-QG-81

AIR TEMP SEN/CIRC*6

P0110

0110

EC-QG-116

CMP SEN/CIRCUIT

P0340

0340

EC-QG-238

COOLANT T SEN/CIRC*3

P0115

0115

EC-QG-120

CKP SEN/CIRCUIT*6

P0335

0335

EC-QG-232

CYL 1 MISFIRE*6

P0301

0301

EC-QG-222

CYL 2 MISFIRE*6

P0302

0302

EC-QG-222

CYL 3 MISFIRE*6

P0303

0303

EC-QG-222

CYL 4 MISFIRE*6

P0304

0304

EC-QG-222

ECM*6

P0605

0605

EC-QG-282

EGR SYSTEM*6*7

P0400

0400

EC-QG-244

EGR SYSTEM*6*7

P1402

1402

EC-QG-305

EGR TEMP SEN/CIRC*6*7

P1401

1401

EC-QG-300

EGR VOL CON/V CIR*6*7

P0403

0403

EC-QG-252

ENG OVER TEMP

P1217

P1217

EC-QG-289

HO2S1 HTR (B1)*6

P0135

0135

EC-QG-166

HO2S1 (B1)*6

P0130

0130

EC-QG-132

HO2S1 (B1)*6

P0131

0131

EC-QG-139

HO2S1 (B1)*6

P0132

0132

EC-QG-145

HO2S1 (B1)*6

P0133

0133

EC-QG-151

HO2S1 (B1)*6

P0134

0134

EC-QG-160

HO2S2 (B1)*6

P0137

0137

EC-QG-171

HO2S2 (B1)*6

P0138

0138

EC-QG-180

HO2S2 (B1)*6

P0139

0139

EC-QG-188

HO2S2 (B1)*6

P0140

0140

EC-QG-197

HO2S2 HTR (B1)*6

P0141

0141

EC-QG-203

FUEL SYS-LEAN/BK1*6

P0171

0171

EC-QG-208

FUEL SYS-RIGH/BK1*6

P0172

0172

EC-QG-215

IACV/AAC VLV/CIRC*6

P0505

0505

EC-QG-274

INT/V TIM V/CIR-B1*6

P1111

1111

EC-QG-284

KNOCK SEN/CIRC-B1

P0325

0325

EC-QG-228

MAF SEN/CIRCUIT*3

P0100

0100

EC-QG-110

MULTI CYL MISFIRE*6

P0300

0300

EC-QG-222

NATS MALFUNCTION

P1610 - P1615

1610 - 1615

Refer to EL section.

P0000

0000

—

NO SELF DIAGNOSTIC FAILURE INDICATED

EC-6

TROUBLE DIAGNOSIS — INDEX

QG16I18DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*5 Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

No DTC

Flashing*4

EC-QG-46

P-N POS SW/CIRCUIT*6

P1706

1706

EC-QG-313

PURG VOLUME CONT/V*6

P0443

0443

EC-QG-262

THRTL POS SEN/CIRC*3

P0120

0120

EC-QG-125

TW CATALYST SYS-B1*6

P0420

0420

EC-QG-258

VEH SPEED SEN/CIRC

P0500

0500

EC-QG-267

NO SELF DIAGNOSTIC FAILURE INDICATED

*1: *2: *3: *4: *5: *6: *7:

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. When the fail-safe operation occurs, the MI illuminates. While engine is running. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped

P NO. INDEX FOR DTC

NCEC0001S02

DTC*5 CONSULT-II GST*2

ECM*1

—

—

No DTC

Items (CONSULT-II screen terms)

Reference page

Unable to access ECM

EC-QG-81

Flashing*4

NO SELF DIAGNOSTIC FAILURE INDICATED

EC-QG-46

P0000

0000

NO SELF DIAGNOSTIC FAILURE INDICATED

—

P0100

0100

MAF SEN/CIRCUIT*3

EC-QG-110

P0110

0110

AIR TEMP SEN/CIRC*6

EC-QG-116

P0115

0115

COOLANT T SEN/CIRC*3

EC-QG-120

P0120

0120

THRTL POS SEN/CIRC*3

EC-QG-125

P0130

0130

HO2S1 (B1)*6

EC-QG-132

P0131

0131

HO2S1 (B1)*6

EC-QG-139

P0132

0132

HO2S1 (B1)*6

EC-QG-145

P0133

0133

HO2S1 (B1)*6

EC-QG-151

P0134

0134

HO2S1 (B1)*6

EC-QG-160

P0135

0135

HO2S1 HTR (B1)*6

EC-QG-166

P0137

0137

HO2S2 (B1)*6

EC-QG-171

P0138

0138

HO2S2 (B1)*6

EC-QG-180

P0139

0139

HO2S2 (B1)*6

EC-QG-188

P0140

0140

HO2S2 (B1)*6

EC-QG-197

P0141

0141

HO2S2 HTR (B1)*6

EC-QG-203

P0171

0171

FUEL SYS-LEAN/BK1*6

EC-QG-208

P0172

0172

FUEL SYS-RICH/BK1*6

EC-QG-215

P0300

0300

MULTI CYL MISFIRE*6

EC-QG-222

P0301

0301

CYL 1 MISFIRE*6

EC-QG-222

EC-7

TROUBLE DIAGNOSIS — INDEX

QG16I18DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*5

*1: *2: *3: *4: *5: *6: *7:

Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

P0302

0302

CYL 2 MISFIRE*6

EC-QG-222

P0303

0303

CYL 3 MISFIRE*6

EC-QG-222

P0304

0304

CYL 4 MISFIRE*6

EC-QG-222

P0325

0325

KNOCK SEN/CIRC-B1

EC-QG-228

P0335

0335

CKP SEN/CIRCUIT *6

EC-QG-232

P0340

0340

CMP SEN/CIRCUIT

EC-QG-238

P0400

0400

EGR SYSTEM*6*7

EC-QG-244

P0403

0403

EGR VOL CON/V CIR*6*7

EC-QG-252

P0420

0420

TW CATALYST SYS-B1*6

EC-QG-258

P0443

0443

PURG VOLUME CONT/V*6

EC-QG-262

P0500

0500

VEH SPEED SEN/CIRC

EC-QG-267

P0505

0505

IACV/AAC VLV/CIRC*6

EC-QG-274

P0605

0605

ECM

EC-QG-282

P1111

1111

INT/V TIM V/CIR-B1*6

EC-QG-284

P1217

1217

ENG OVER TEMP

EC-QG-289

P1401

1401

EGR TEMP SEN/CIRC*6*7

EC-QG-300

P1402

1402

EGR SYSTEM*6*7

EC-QG-305

P1610 - 1615

1610 - 1615

P1706

1706

NATS MALFUNCTION P-N POS SW/CIRCUIT*6

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. When the fail-safe operation occurs, the MI illuminates. While engine is running. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped

EC-8

Refer to EL section. EC-QG-313

PRECAUTIONS

QG16I18DE

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

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

NCEC0002

The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).

Precautions for On Board Diagnostic (OBD) System of Engine

NCEC0003

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) I Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL section, “Description”, “HARNESS CONNECTOR”. I Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. I Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the EGR system or fuel injection system, etc. I Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.

EC-9

PRECAUTIONS

QG16I18DE

Engine Fuel & Emission Control System

Engine Fuel & Emission Control System

NCEC0004

SEF331WB

EC-10

PRECAUTIONS

QG16I18DE Precautions

Precautions

NCEC0005

I

Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.

I

When connecting or disconnecting ECM harness connector, use lever as shown. When connecting, fasten connector securely with lever moved until it stops.

I

When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminals when connecting pin connectors.

I

Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-QG-91.

I

After performing each TROUBLE DIAGNOSIS, perform “Overall Function Check” or “DTC Confirmation Procedure”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall Function Check” should be a good result if the repair is completed.

SEF289H

SEF908W

SEF291H

MEF040D

SAT652J

EC-11

PRECAUTIONS

QG16I18DE

Precautions (Cont’d)

I

I

When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

SEF348N

Wiring Diagrams and Trouble Diagnosis

NCEC0006

When you read Wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section

EC-12

QG16I18DE

PREPARATION

Special Service Tools

Special Service Tools Tool number Tool name

NCEC0007

Description

KV10117100 Heated oxygen sensor wrench

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

NT379

KV10114400 Heated oxygen sensor wrench

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

NT636

Commercial Service Tool Tool name

NCEC0008

Description

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening pressure

NT653

Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below. a: 18 mm dia. with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm dia. with pitch 1.25 mm for Titania Oxygen Sensor

NT778

Anti-seize lubricant (PermatexTM 133AR or equivalent meeting MIL specification MIL-A-907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

NT779

EC-13

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location

Engine Control Component Parts Location

NCEC0009

YEC128A

EC-14

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location (Cont’d)

YEC129A

EC-15

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Engine Control Component Parts Location (Cont’d)

SEF911W

EC-16

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Circuit Diagram

Circuit Diagram

NCEC0010

YEC062A

EC-17

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE System Diagram

System Diagram

NCEC0011

YEC116A

EC-18

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE Vacuum Hose Drawing

Vacuum Hose Drawing

NCEC0012

Refer to “System Diagram” on EC-QG-18 for vacuum control system.

Fuel pressure regulator EVAP canister purge pipe (to EVAP canister)

To air control valve (Power steering)

To air duct

EVAP canister purge volume control solenoid valve EVAP canister

Air Fuel tank NEF231A

EC-19

ENGINE AND EMISSION CONTROL OVERALL SYSTEM QG16I18DE System Chart

System Chart Input (Sensor) I I I I I I I I I I I I I I I I I I

Camshaft position sensor (PHASE) Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 (front) Ignition switch Throttle position sensor PNP switch Air conditioner switch Knock sensor EGR temperature sensor*1*3 Crankshaft position sensor (POS) Battery voltage Power steering oil pressure switch Vehicle speed sensor or ABS actuator and electric unit (control unit) Intake air temperature sensor Heated oxygen sensor 2 (rear)*2 Electrical load Refrigerant pressure sensor

NCEC0013

ECM Function

Output (Actuator)

Fuel injection & mixture ratio control

Injectors

Electronic ignition system

Power transistor

Idle air control system

IACV-AAC valve

Valve timing control

Intake valve timing control solenoid valve

Fuel pump control

Fuel pump relay

Heated oxygen sensor 1 monitor & on board diagnostic system

Malfunction indicator (On the instrument panel)

EGR control*3

EGR volume control valve*3

Heated oxygen sensor 1, 2 heater control

Heated oxygen sensor heater

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Cooling fan control

Cooling fan relay

Air conditioning cut control

Air conditioner relay

*1: This sensor is not used to control the engine system. They are used only for the on board diagnosis. *2: Under normal conditions, this sensor is not for engine control operation. *3: If so equipped

EC-20

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Multiport Fuel Injection (MFI) System

Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart

NCEC0014 NCEC0014S01

Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed and piston position

Camshaft position sensor (PHASE)

Cylinder number

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1 (front)

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position Throttle valve idle position

PNP switch

Gear position

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Ignition switch

Start signal

Air conditioner switch

Air conditioner operation

Knock sensor

Engine knocking condition

Electrical load

Electrical load signal

Battery

Battery voltage

Power steering oil pressure switch

Power steering operation

Heated oxygen sensor 2 (rear)*

Density of oxygen in exhaust gas

ECM function

Fuel injection & mixture ratio control

Actuator

Injector

* Under normal conditions, this sensor is not for engine control operation.

Basic Multiport Fuel Injection System

NCEC0014S02

The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from both the camshaft position sensor and the mass air flow sensor.

Various Fuel Injection Increase/Decrease Compensation

NCEC0014S03

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. I During warm-up I When starting the engine I During acceleration I Hot-engine operation I High-load, high-speed operation I During deceleration I During high engine speed operation I During high vehicle speed operation (M/T models) I Extremely high engine coolant temperature

EC-21

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Multiport Fuel Injection (MFI) System (Cont’d)

Mixture Ratio Feedback Control (Closed loop control)

NCEC0014S04

SEF336WA

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 (front) in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about the heated oxygen sensor 1 (front), refer to EC-QG-132. This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 (rear) is located downstream of the three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 (front) shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2 (rear).

Open Loop Control

NCEC0014S05

The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. I Deceleration and acceleration I High-load, high-speed operation I Malfunction of heated oxygen sensor 1 (front) or its circuit I Insufficient activation of heated oxygen sensor 1 (front) at low engine coolant temperature I High engine coolant temperature I During warm-up I When starting the engine

Mixture Ratio Self-learning Control

NCEC0014S06

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1 (front). This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot film) and characteristic changes during operation (i.e., injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from the heated oxygen sensor 1 (front) indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment.

EC-22

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Multiport Fuel Injection (MFI) System (Cont’d)

Fuel Injection Timing

NCEC0014S07

SEF337W

Two types of systems are used. Sequential Multiport Fuel Injection System NCEC0014S0701 Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. Simultaneous Multiport Fuel Injection System NCEC0014S0702 Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The four injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

Fuel Shut-off

NCEC0014S08

Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

Electronic Ignition (EI) System DESCRIPTION Input/Output Signal Chart Sensor

NCEC0015 NCEC0015S01

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed and piston position

Camshaft position sensor (PHASE)

Cylinder number

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position Throttle valve idle position

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Ignition switch

Start signal

Knock sensor

Engine knocking

PNP switch

Gear position

Battery

Battery voltage

EC-23

ECM function

Actuator

Ignition timPower transistor ing control

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Electronic Ignition (EI) System (Cont’d)

System Description

NCEC0015S02

SEF742M

The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map shown above. The ECM receives information such as the injection pulse width, crankshaft position sensor signal and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. e.g., N: 1,800 rpm, Tp: 1.50 msec A°BTDC During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. I At starting I During warm-up I At idle I During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor

NCEC0016 NCEC0016S01

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

Throttle position sensor

Throttle valve opening angle

Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Refrigerant pressure sensor

Refrigerant pressure

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Power steering oil pressure switch

Power steering operation

ECM function

Air conditioner cut control

Actuator

Air conditioner relay

System Description

NCEC0016S02

This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. I When the accelerator pedal is fully depressed. I When cranking the engine. I At high engine speeds. I When the engine coolant temperature becomes excessively high. I When operating power steering during low engine speed or low vehicle speed. I When engine speed is excessively low.

EC-24

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Fuel Cut Control (at no load & high engine speed)

Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart Sensor

NCEC0017 NCEC0017S01

Input Signal to ECM

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

PNP switch

Neutral position

Throttle position sensor

Throttle position

Engine coolant temperature sensor

Engine coolant temperature

Crankshaft position sensor (POS)

Engine speed

ECM function

Fuel cut control

Actuator

Injectors

If the engine speed is above 3,950 rpm with no load, (for example, in Neutral and engine speed over 4,000 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 1,150 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-QG-21.

Evaporative Emission System DESCRIPTION

NCEC0018

SEF916WA

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and idling.

EC-25

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Evaporative Emission System (Cont’d)

INSPECTION EVAP Canister

NCEC0019 NCEC0019S01

Check EVAP canister as follows: 1. Block port B. Orally blow air through port A. Check that air flows freely through port C with check valve resistance. 2. Block port A. Orally blow air through port B. Check that air flows freely through port C.

SEF917W

Fuel Tank Vacuum Relief Valve (Built into fuel fillerNCEC0019S03 cap) 1. 2.

SEF918W

3.

Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 16.0 - 20.0 kPa (0.16 - 0.20 bar, 0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.060 to −0.035 bar, −0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) If out of specification, replace fuel filler cap as an assembly.

Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve NCEC0019S07 Refer to EC-QG-266.

SEF943S

EC-26

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Evaporative Emission System (Cont’d)

EVAPORATIVE EMISSION LINE DRAWING

NCEC0020

SEF919W

EC-27

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

QG16I18DE

Positive Crankcase Ventilation

Positive Crankcase Ventilation DESCRIPTION

NCEC0022

SEF921W

This system returns blow-by gas to the intake collector. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air duct into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the intake collector under all conditions.

INSPECTION PCV (Positive Crankcase Ventilation) Valve

NCEC0023 NCEC0023S01

With engine running at idle, remove PCV valve from breather separator. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over the valve inlet.

SEC137A

Ventilation Hose 1. 2.

NCEC0023S02

Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

ET277

EC-28

BASIC SERVICE PROCEDURE

QG16I18DE Fuel Pressure Release

Fuel Pressure Release

NCEC0024

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

WITH CONSULT-II 1. 2. 3. PEF823K

4.

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

NCEC0024S01

Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode with CONSULT-II. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. NCEC0024S02

Remove fuse for fuel pump. Refer to fuse block cover for fuse location. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF and reconnect fuel pump fuse.

SEF922W

Fuel Pressure Check I I I I I

SEF925W

1. 2. 3. 4. 5.

NCEC0025

When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. Release fuel pressure to zero. Disconnect fuel hose between fuel filter and fuel tube (engine side). Install pressure gauge between fuel filter and fuel tube. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idle speed: With vacuum hose connected Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi)

EC-29

BASIC SERVICE PROCEDURE

QG16I18DE

Fuel Pressure Regulator Check

If results are unsatisfactory, perform Fuel Pressure Regulator Check, EC-QG-30.

Fuel Pressure Regulator Check

NCEC0026

1.

Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 2. Plug intake manifold with a rubber cap. 3. Connect variable vacuum source to fuel pressure regulator. 4. Start engine and read indication of fuel pressure gauge as vacuum is changed. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. SEF718B

Injector REMOVAL AND INSTALLATION 1. 2.

SEF926W

3. 4. I I I 5. I I I I I

SEF927W

I 6. I

NCEC0027

Release fuel pressure to zero. Remove fuel tube assemblies in numerical sequence as shown in the Figure at left. Expand and remove clips securing fuel injectors. Extract fuel injectors straight from fuel tubes. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble or adjust fuel injectors. Install fuel injectors. Carefully install O-rings, including the one used with the pressure regulator. Use bare hands to install O-rings. Do not wear gloves. Apply a coat of engine oil (with a low viscosity of 5W-30, etc.) to O-rings before installation. Do not use solvent to clean O-rings and other parts. Make sure that O-rings and other parts are clean and free from foreign particles. Be careful not to damage O-rings with service tools or finger nails. Do not expand or twist O-rings. If stretched, do not insert them into fuel tubes immediately after stretching. Always insert O-rings straight into fuel tubes. Do not tilt or rotate them during installation. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.

EC-30

BASIC SERVICE PROCEDURE

QG16I18DE Injector (Cont’d)

SEF928W

7. 8. I

Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips. Discard old clips; replace with new ones.

9.

SEF929W

Tighten fuel tube assembly mounting nuts in numerical sequence (indicated in the Figure at left) and in two stages. : Tightening torque N⋅m (kg-m, ft-lb) 1st stage: 12 - 13 (1.2 - 1.4, 9 - 10) 2nd stage: 17 - 23 (1.7 - 2.4, 13 - 17) 10. Insert fuel hoses into fuel tubes so that ends of fuel hoses butt up against fuel tubes; fasten with clamps, avoiding bulges. CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.

EC-31

BASIC SERVICE PROCEDURE

QG16I18DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

NCEC0028

DIRECT IGNITION SYSTEM — HOW TO CHECK IDLE SPEED AND IGNITION TIMING NCEC0028S03 Idle Speed NCEC0028S0301 I

Using CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULTII.

NEF059A

Ignition Timing

NCEC0028S0302

Any of following two methods may be used. I Method A a) Attach timing light to loop wire as shown. b) Check ignition timing.

SEF931W

I a) b)

c)

Method B Remove No. 1 ignition coil. Connect No. 1 ignition coil and No. 1 spark plug with suitable high-tension wire as shown, and attach timing light clamp to this wire. Check ignition timing.

SEF933W

SEF284G

EC-32

BASIC SERVICE PROCEDURE

QG16I18DE Idle Air Volume Learning

SEF311Q

Idle Air Volume Learning DESCRIPTION

NCEC0541 NCEC0541S01

“Idle Air Volume Learning” is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: I Each time IACV-AAC valve, throttle body or ECM is replaced. I Idle speed or ignition timing is out of specification.

PRE-CONDITIONING SEF452Y

SEF454Y

OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. SEF455Y

NCEC0541S04

Before performing “Idle Air Volume Learning”, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. I Battery voltage: More than 12.9V (At idle) I Engine coolant temperature: 70 - 99°C (158 - 210°F) I PNP switch: ON I Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps. I Cooling fan motor: Not operating I Steering wheel: Neutral (Straight-ahead position) I Vehicle speed: Stopped I Transmission: warmed-up (Drive vehicle for 10 minutes.) NCEC0541S02 NCEC0541S0201

Turn ignition switch “ON” and wait at least 1 second. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and warm it up to normal operating temperature. Check that all items listed under the topic “PRE-CONDITIONING” (previously mentioned) are in good order.

EC-33

QG16I18DE

BASIC SERVICE PROCEDURE Idle Air Volume Learning (Cont’d)

5. 6. 7. 8. 9.

Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and let it to idle for at least 28 seconds. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. Touch “START” and wait 20 seconds. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “INCMP” is displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the problem by referring to the NOTE below. 10. Rev up the engine two or three times. Make sure that idle speed and ignition timing are close to or within specifications.

Throttle body

.

Remove or install throttle position sensor harness connector (brown)

IACV-AAC valve harness connector NEF246A

ITEM

SPECIFICATION

Idle speed

700 ± 50 rpm

Ignition timing

8° ± 5° BTDC

Without CONSULT-II

NCEC0541S0202

1. 2. 3.

Turn ignition switch “ON” and wait at least 1 second. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and warm it up to normal operating temperature. 4. Check that all items listed under the topic “PRE-CONDITIONING” (previously mentioned) are in good order. 5. Turn ignition switch “OFF” and wait at least 9 seconds. 6. Start the engine and let it to idle for at least 28 seconds. 7. Disconnect throttle position sensor harness connector (brown), then re-connect it within 5 seconds. 8. Wait 20 seconds. 9. Make sure that idle speed is within specifications. If not, the result will be incomplete. In this case, find the cause of the problem by referring to the NOTE below. 10. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications. ITEM

SPECIFICATION

Idle speed

700 ± 50 rpm

Ignition timing

8° ± 5° BTDC

NOTE: If idle air volume learning cannot be performed successfully, proceed as follows: 1) Check that throttle valve is fully closed. 2) Check PCV valve operation. 3) Check that downstream of throttle valve is free from air leakage. 4) Adjust closed throttle position switch and reset memory. (Refer to Basic Inspection, EC-QG-72.) 5) When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the problem. 6) If any of the following conditions occur after the engine has started, eliminate the cause of the problem and perform “Idle air volume learning” all over again:

EC-34

BASIC SERVICE PROCEDURE

QG16I18DE Idle Air Volume Learning (Cont’d)

I I I

Engine stalls. Erroneous idle. Blown fuses related to IACV-AAC valve system.

EC-35

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction

Introduction

NCEC0029

The ECM has an on board diagnostic system which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Diagnostic Trouble Code (DTC)

Mode 3 of ISO15031-5

Freeze Frame data

Mode 2 of ISO15031-5

System Readiness Test (SRT) code

Mode 1 of ISO15031-5

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of ISO15031-5

1st Trip Freeze Frame data Test values and Test limits

Mode 6 of ISO15031-5

Calibration ID

Mode 9 of ISO15031-5

The above information can be checked using procedures listed in the table below. X: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame data

1st trip Freeze Frame data

SRT code

Test value

ECM*3

X

X*1

—

—

—

—

CONSULT-II*4

X

X

X

X

X

—

GST*4

X

X*2

X

—

X

X

*1: *2: *3: *4:

When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display. In diagnostic test mode II (Self-diagnostic results), DTC is displayed on MI. DTC uses a set of four digit numbers. In SELF-DIAGNOSTIC RESULTS mode, DTC is displayed. DTC uses “P” and a set of four digit numbers.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-QG-81.)

Two Trip Detection Logic

NCEC0030

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage <1st trip>. If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored <2nd trip>. The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. X: Applicable MI

DTC

1st trip

Items

2nd trip

—: Not applicable 1st trip DTC

1st trip displaying

2nd trip displaying

1st trip displaying

2nd trip displaying

—

—

—

X

—

X

—

—

X

—

—

X

—

—

X*1

—

X*1

—

—

—

X

—

X

X

X

Blinking

Lighting up

Blinking

Lighting up

Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected

X

—

—

Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected

—

—

Fail-safe items (Refer to EC-QG-81.)

—

Except above

—

*1: Except “ECM”.

EC-36

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information

Emission-related Diagnostic Information DTC AND 1ST TRIP DTC

NCEC0031 NCEC0031S01

The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory. Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”. Refer to EC-QG-44. For malfunctions in which 1st trip DTCs are displayed, refer to EC-QG-42. These items are required by legal regulations to continuously monitor the system/component. In addition, the items monitored non-continuously are also displayed on CONSULT-II. 1st trip DTC is specified in Mode 7 of ISO15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a problem. However, 1st trip DTC detection will not prevent the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests. When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in “Work Flow” procedure Step II, refer to page EC-QG-70. Then perform “DTC Confirmation Procedure” or “Overall Function Check” to try to duplicate the problem. If the malfunction is duplicated, the item requires repair.

How to read DTC and 1st Trip DTC

NCEC0031S0101

DTC and 1st trip DTC can be read by the following methods. 1) No Tools The number of blinks of MI in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0340, 1320, 0705, 0750, etc. These DTCs are controlled by NISSAN. With CONSULT-II 2) With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc. These DTCs are prescribed by ISO15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I Output of a DTC indicates a malfunction. However, Mode II and GST do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be “0”. If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

DTC display

1st trip DTC display

NEF065A

EC-37

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

NCEC0031S02

The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed and absolute pressure sensor at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For details, see EC-QG-58. Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1

Items Freeze frame data

2 3

Misfire — DTC: P0300 - P0304 (0300 - 0304) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172) Except the above items

1st trip freeze frame data

For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the ECM memory. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION”. Refer to EC-QG-44.

SYSTEM READINESS TEST (SRT) CODE

NCEC0031S03

System Readiness Test (SRT) code is specified in Mode 1 of ISO15031-5. It indicates whether the self-diagnostic tests for non-continuously monitored items have been completed or not. Inspection/Maintenance (I/M) tests of the on board diagnostic (OBD) II system may become the legal requirements in some states/areas. All SRT codes must be set in this case. Unless all SRT codes are set, conducting the I/M test may not be allowed. SRT codes are set after self-diagnosis has been performed one or more times. This occurs regardless of whether the diagnosis is in “OK” or “NG”, and whether or not the diagnosis is performed in consecutive trips. The following table lists the four SRT items (14 test items) for the ECM used in P11 models. SRT items

Self-diagnostic test items

Catalyst monitoring

I Three way catalyst function P0420 (0420)

Oxygen sensor monitoring

I I I I I I I I I

Oxygen sensor heater monitoring

I Heated oxygen sensor 1 (front) heater P0135 (0135) I Heated oxygen sensor 2 (rear) heater P0141 (0141)

EGR system monitoring (If so equipped)

I EGR function (Close) P0400 (0400) I EGR function (Open) P1402 (1402)

Heated Heated Heated Heated Heated Heated Heated Heated Heated

oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen

sensor sensor sensor sensor sensor sensor sensor sensor sensor

EC-38

1 1 1 1 1 2 2 2 2

(front) (Circuit) P0130 (0130) (front) (Lean shift monitoring) P0131 (0131) (front) (Rich shift monitoring) P0132 (0132) (front) (Response monitoring) P0133 (0133) (front) (High voltage) P0134 (0134) (rear) (Min. voltage monitoring) P0137 (0137) (rear) (Max. voltage monitoring) P0138 (0138) (rear) (Response monitoring) P0139 (0139) (rear) (High voltage) P0140 (0140)

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

Together with the DTC, the SRT code is cleared from the ECM memory using the method described later (Refer to EC-QG-44). In addition, after engine control components/system are repaired or if the battery terminals remain disconnected for more than 24 hours, all SRT codes may be cleared from the ECM memory.

How to Display SRT Code 1.

NCEC0031S0301

With CONSULT-II Selecting “SRT STATUS” in “DTC CONFIRMATION” mode with CONSULT-II. For items whose SRT codes are set, a “CMPLT” is displayed on the CONSULT-II screen; for items whose SRT codes are not set, “INCMP” is displayed as shown below.

SEF821Y

2.

With GST Selecting Mode 1 with GST (Generic Scan Tool)

How to Set SRT Code

NCEC0031S0302

To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The driving pattern should be performed one or more times to set all SRT codes.

EC-39

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

Driving Pattern

NCEC0031S0303

YEC130A

EC-40

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

I

The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc. Zone A refers to the range where the time required, for the diagnosis under normal conditions*, is the shortest. Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed within zone A. *: Normal conditions refer to the following: − − − −

Sea level Flat road Ambient air temperature: 20 - 30°C (68 - 86°F) Diagnosis is performed as quickly as possible under normal conditions. Under different conditions [For example: ambient air temperature other than 20 - 30°C (68 - 86°F)], diagnosis may also be performed.

Pattern 1: I The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminals 70 and 58 is 3.0 - 4.3V). I The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminals 70 and 58 is lower than 1.4V). Pattern 2: I When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended. *1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH) again. *2: Checking the vehicle speed with CONSULT-II or GST is advised. *3: The driving pattern may be omitted when all the followings are performed using the “DTC WORK SUPPORT” mode with CONSULT-II. I “EGR SYSTEM P0400” (If so equipped) I “EGR SYSTEM P1402” (If so equipped) Suggested upshift speeds Shown below are suggested vehicle speeds for shifting into a higher gear. These suggestions relate to fuel economy and vehicle performance. Actual upshift speeds will vary according to road conditions, the weather and individual driving habits. Gear change

ACCEL shift point km/h (MPH)

1st to 2nd

15 (9)

2nd to 3rd

35 (22)

3rd to 4th

50 (31)

4th to 5th

70 (43)

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

NCEC0031S04

The following is the information specified in Mode 6 of ISO15031-5. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. Items for which these data (test value and test limit) are displayed are the same as SRT code items (6 test items). These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. X: Applicable

—: Not applicable

Test limit

Application

Test value (GST display) SRT item

CATALYST

Self-diagnostic test item TID

CID

01H

01H

Max.

X

02H

81H

Min.

X

Three way catalyst function

EC-41

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item

Self-diagnostic test item

Heated oxygen sensor 1 (front)

HO2S

Heated oxygen sensor 2 (rear)

Heated oxygen sensor 1 (front) heater

Test limit

Application

04H

Max.

X

0AH

84H

Min.

X

0BH

04H

Max.

X

0CH

04H

Max.

X

0DH

04H

Max.

X

19H

86H

Min.

X

1AH

86H

Min.

X

1BH

06H

Max.

X

1CH

06H

Max.

X

29H

08H

Max.

X

2AH

88H

Min.

X

2DH

0AH

Max.

X

2EH

8AH

Min.

X

31H

8CH

Min.

X

32H

8CH

Min.

X

33H

8CH

Min.

X

34H

8CH

Min.

X

35H

0CH

Max.

X

X: Applicable

—: Not applicable

TID

CID

09H

HO2S HTR Heated oxygen sensor 2 (rear) heater

EGR SYSTEM (If so equipped)

EGR function (If so equipped)

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS DTC*4 Items (CONSULT-II screen terms)

NCEC0031S05

SRT code

Test value/Test limit (GST only)

1st trip DTC*4

Reference page

CONSULT-II GST*2

ECM*1

NO SELF DIAGNOSTIC FAILURE INDICATED

P0000

0000

—

—

—

—

MAF SEN/CIRCUIT

P0100

0100

—

—

X

EC-QG-110

AIR TEMP SEN/CIRC

P0110

0110

—

—

X

EC-QG-116

COOLANT T SEN/CIRC

P0115

0115

—

—

X

EC-QG-120

THRTL POS SEN/CIRC

P0120

0120

—

—

X

EC-QG-125

HO2S1 (B1)*5

P0130

0130

X

X

X*3

EC-QG-132

HO2S1 (B1)*5

P0131

0131

X

X

X*3

EC-QG-139

HO2S1 (B1)*5

P0132

0132

X

X

X*3

EC-QG-145

HO2S1 (B1)*5

P0133

0133

X

X

X*3

EC-QG-151

HO2S1 (B1)*5

P0134

0134

X

X

X*3

EC-QG-160

HO2S1 HTR (B1)*5

P0135

0135

X

X

X*3

EC-QG-166

HO2S2 (B1)*5

P0137

0137

X

X

X*3

EC-QG-171

HO2S2 (B1)*5

P0138

0138

X

X

X*3

EC-QG-180

HO2S2 (B1)*5

P0139

0139

X

X

X*3

EC-QG-188

EC-42

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d) DTC*4 SRT code

Test value/Test limit (GST only)

1st trip DTC*4

Reference page

0140

X

X

X*3

EC-QG-197

P0141

0141

X

X

X*3

EC-QG-203

FUEL SYS LEAN/BK1*5

P0171

0171

—

—

X

EC-QG-208

FUEL SYS RICH/BK1*5

P0172

0172

—

—

X

EC-QG-215

MULTI CYL MISFIRE*5

P0300

0300

—

—

X

EC-QG-222

CYL 1 MISFIRE*5

P0301

0301

—

—

X

EC-QG-222

CYL 2 MISFIRE*5

P0302

0302

—

—

X

EC-QG-222

CYL 3 MISFIRE*5

P0303

0303

—

—

X

EC-QG-222

CYL 4 MISFIRE*5

P0304

0304

—

—

X

EC-QG-222

KNOCK SEN/CIRC-B1

P0325

0325

—

—

—

EC-QG-228

CKP SEN/CIRCUIT *5

P0335

0335

—

—

X

EC-QG-232

CMP SEN/CIRCUIT

P0340

0340

—

—

X

EC-QG-238

EGR SYSTEM*5*6

P0400

0400

X

X

X*3

EC-QG-244

EGR VOL CON/V CIR*5*6

P0403

0403

—

—

X

EC-QG-252

TW CATALYST SYS-B1*5

P0420

0420

X

X

X*3

EC-QG-258

PURG VOLUME CONT/V*5

P0443

0443

—

—

X

EC-QG-262

VEH SPEED SEN/CIRC

P0500

0500

—

—

X

EC-QG-267

IACV/AAC VLV/CIRC*5

P0505

0505

—

—

X

EC-QG-274

ECM

P0605

0605

—

—

X

EC-QG-282

INT/V TIM V/CIR-B1*5

P1111

1111

—

—

X

EC-QG-284

ENG OVER TEMP

P1217

1217

—

—

X

EC-QG-289

EGR TEMP SEN/CIRC*5*6

P1401

1401

—

—

X

EC-QG-300

EGR SYSTEM*5*6

P1402

1402

X

X

X*3

EC-QG-305

P-N POS SW/CIRCUIT*5

P1706

1706

—

—

X

EC-QG-313

Items (CONSULT-II screen terms)

CONSULT-II GST*2

ECM*1

HO2S2 (B1)*5

P0140

HO2S2 HTR (B1)*5

*1: *2: *3: *4: *5: *6:

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO15031-6. These are not displayed with GST. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe model”. If so equipped

EC-43

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC (With CONSULT-II)

NCEC0031S06 NCEC0031S0601

1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again. 2. Touch “ENGINE”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.)

SEF950W

The emission-related diagnostic information can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II.

How to Erase DTC (With GST)

NCEC0031S0602

1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again.

EC-44

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Emission-related Diagnostic Information (Cont’d)

2. Select Mode 4 with GST (Generic Scan Tool). The emission-related diagnostic information can be erased by selecting Mode 4 with GST (Generic Scan Tool).

How to Erase DTC (No Tools)

NCEC0031S0603

1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” again. 2. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-QG48.) The emission-related diagnostic information can be erased by changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by using the data link connector. (Refer to EC-QG-48.) NOTE: I If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. I Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode using the data link connector. I The following data are cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures.

Malfunction Indicator (MI) NATS (Nissan Anti-Theft System)

SEF543X

I I I

If the security indicator lights up with the ignition switch in the “ON” position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to “NATS (Nissan Anti-Theft System)” in EL section. Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.

EC-45

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Malfunction Indicator (MI) (Cont’d)

DESCRIPTION

NCEC0032

SAT652J

The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. I If the MI does not light up, refer to EL section (“WARNING LAMPS”) or see EC-QG-354. 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction.

On Board Diagnostic System Function

=NCEC0032S01

The on board diagnostic system has the following four functions. Diagnostic Test Mode I 1. BULB CHECK: This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit and ECM test mode selector. (See the following page.) 2. MALFUNCTION WARNING: This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MI in the 1st trip. I “Misfire (Possible three way catalyst damage)” I Fail-safe mode Diagnostic Test Mode II 3. SELF-DIAGNOSTIC RESULTS: This function allows DTCs and 1st trip DTCs to be read. 4. HEATED OXYGEN SENSOR 1 (FRONT) MONITOR: This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1 (front), to be read. MI Flashing without DTC NCEC0032S0101 If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM test mode selector following “HOW TO SWITCH DIAGNOSTIC TEST MODES”. How to switch the diagnostic test (function) modes, and details of the above functions are described later. (Refer to EC-QG-48.)

EC-46

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Malfunction Indicator (MI) (Cont’d) Condition

Diagnostic Test Mode I

Diagnostic Test Mode II

BULB CHECK

SELF-DIAGNOSTIC RESULTS

MALFUNCTION WARNING

HEATED OXYGEN SENSOR 1 (FRONT) MONITOR

Engine stopped Ignition switch in “ON” position Engine running

The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others

EC-47

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Malfunction Indicator (MI) (Cont’d)

How to Switch Diagnostic Test Modes

NCEC0032S02

SEF951WA

*1: EC-QG-354 *2: EC-QG-46

*3: EC-QG-354

EC-48

*4: EC-QG-81

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Malfunction Indicator (MI) (Cont’d)

Diagnostic Test Mode I — Bulb Check

NCEC0032S03

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the MI bulb. Refer to EL section (“WARNING LAMPS”) or see EC-QG-354.

Diagnostic Test Mode I — Malfunction Warning MI

I

NCEC0032S04

Condition

ON

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS).

Diagnostic Test Mode II — Self-diagnostic Results

NCEC0032S05

In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a code.

SEF952W

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second)-OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0 second OFF. In other words, the latter numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8 second off. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC “0000” refers to no malfunction. (See TROUBLE DIAGNOSIS — INDEX, EC-QG-6.) How to Erase Diagnostic Test Mode II (Self-diagnostic results) NCEC0032S0501 The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODES”.) I If the battery is disconnected, the DTC will be lost from the backup memory after approx. 24 hours. I Be careful not to erase the stored memory before starting trouble diagnoses.

EC-49

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator (MI) (Cont’d)

Diagnostic Test Mode II — Heated Oxygen Sensor (Front) Monitor

NCEC0032S06

In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1 (front). MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

Air fuel ratio feedback control condition Closed loop system Open loop system

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 (front) function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no-load.

OBD System Operation Chart

NCEC0033

RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS I I I I

I

NCEC0033S01

When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are stored in the ECM memory. When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are stored in the ECM memory, and the MI will come on. For details, refer to “Two Trip Detection Logic” on EC-QG-36. The MI will go off after the vehicle is driven 3 times with no malfunction. The drive is counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting, the counter will reset. The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A) without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven. The 1st trip DTC is not displayed when the self-diagnosis results in “OK” for the 2nd trip.

SUMMARY CHART Items MI (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)

NCEC0033S02

Fuel Injection System

Misfire

Other

3 (pattern B)

3 (pattern B)

3 (pattern B)

80 (pattern C)

80 (pattern C)

40 (pattern A)

1 (pattern C), *1

1 (pattern C), *1

1 (pattern B)

*1, *2

*1, *2

1 (pattern B)

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-QG-52. For details about patterns “A” and “B” under “Except”, see EC-QG-54. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip.

EC-50

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” <EXHAUST QUALITY DETERIORATION>, “FUEL INJECTION SYSTEM”

NCEC0033S03

SEF392S

*1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame

data will not be displayed any longer after vehicle is driven 80 times (pattern C) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: The 1st trip DTC and the 1st trip

EC-51

freeze frame data will be cleared at the moment OK is detected. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. *8: 1st trip DTC will be cleared when vehicle is driven once (pattern C) without the same malfunction after DTC is stored in ECM.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” Driving Pattern B

NCEC0033S04 NCEC0033S0401

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunction. I The MI will go off when the B counter reaches 3. (*2 in EC-QG-51)

Driving Pattern C

NCEC0033S0402

Driving pattern C means the vehicle operation as follows: 1) The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) × (1±0.1) [%] Engine coolant temperature (T) condition: I When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). I When the freeze frame data shows higher than or equal to 70°C (158°F), “T” should be higher than or equal to 70°C (158°F). Example: If the stored freeze frame data is as follows: Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F) To be satisfied with driving pattern C, the vehicle should run under the following conditions: Engine speed: 475 - 1,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more than 70°C (158°F) I The C counter will be cleared when the malfunction is detected regardless of driving pattern C. I The C counter will be counted up when driving pattern C is satisfied without the same malfunction. I The DTC will not be displayed after C counter reaches 80. I The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.

EC-52

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S05

SEF393S

*1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM.

*4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 40 times (pattern A) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC

EC-53

and the 1st trip freeze frame data will be stored in ECM. *6: 1st trip DTC will be cleared after vehicle is driven once (pattern B) without the same malfunction. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S06 Driving Pattern A NCEC0033S0601

AEC574

I I I

The A counter will be cleared when the malfunction is detected regardless of (1) - (4). The A counter will be counted up when (1) - (4) are satisfied without the same malfunction. The DTC will not be displayed after the A counter reaches 40.

Driving Pattern B

NCEC0033S0602

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunctions. I The MI will go off when the B counter reaches 3 (*2 in EC-QG-53).

EC-54

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE CONSULT-II

CONSULT-II CONSULT-II INSPECTION PROCEDURE

=NCEC0034 NCEC0034S01

1. 2.

Turn ignition switch OFF. Connect “CONSULT-II” to data link connector. (Data link connector is located behind the fuse box cover.)

3. 4.

Turn ignition switch ON. Touch “START”.

5.

Touch “ENGINE”.

SEF922W

PBR455D

PEF895K

6.

Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

NEF244A

EC-55

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NCEC0034S02 DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS

ENGINE CONTROL COMPONENT PARTS

Item

INPUT

WORK SUPPORT

DTC*1

FREEZE FRAME DATA*2

Camshaft position (PHASE) sensor

X

X

Mass air flow sensor

X

Engine coolant temperature sensor

X

Heated oxygen sensor 1 (Front)

DATA MONITOR

DATA MONI- ACTIVE TOR TEST (SPEC)

DTC & SRT CONFIRMATION SRT STATUS

SRT DTC WORK WORK SUPSUPPORT PORT

X

X

X

X

X

X

X

X

X

X

X

X

Heated oxygen sensor 2 (rear)

X

X

X

X

X

X

Vehicle speed sensor or ABS actuator and electric unit (control unit)

X

X

X

Throttle position sensor

X

X

X

EGR temperature sensor (If so equipped)

X

X

X

Intake air temperature sensor

X

X

X

Crankshaft position sensor (POS)

X

X

X

Knock sensor

X

Ignition switch (start signal)

X

X

Closed throttle position switch (throttle position sensor signal)

X

X

Air conditioner switch

X

X

Refrigerant pressure sensor

X

X

X

X

Power steering oil pressure switch

X

X

Electrical load

X

X

Battery voltage

X

X

Park/Neutral position (PNP) switch

X

X

X

X

EC-56

X

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS WORK SUPPORT

Item

DTC*1

FREEZE FRAME DATA*2

DATA MONITOR

Injectors

ENGINE CONTROL COMPONENT PARTS

Power transistor (Ignition timing) IACV-AAC valve

X

X

X

X

X (Ignition signal)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

Intake valve timing control solenoid valve EVAP canister purge volume control solenoid valve OUTPUT

X

Air conditioner relay Fuel pump relay

DATA MONI- ACTIVE TOR TEST (SPEC)

X

DTC & SRT CONFIRMATION SRT STATUS

EGR volume control valve (If so equipped)

X

X

X

Heated oxygen sensor heater 1 (front)

X

X

X

X

Heated oxygen sensor heater 2 (rear)

X

X

X

X

Cooling fan

X

X

X

X

X

Calculated load value

X

X

SRT DTC WORK WORK SUPSUPPORT PORT

X

X

X

X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-QG-38.

FUNCTION Diagnostic test mode

NCEC0034S03

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.*1

Data monitor

Input/Output data in the ECM can be read.

Data monitor (spec)

Input/Output specifications of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read.

Active test

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

DTC confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

ECM part number

ECM part numbers can be read.

*1 The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data

EC-57

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) 4) 5) 6) 7) 8)

1st trip freeze frame data System readiness test (SRT) codes Test values Distance traveled while MI is activated. Others

WORK SUPPORT MODE WORK ITEM

NCEC0034S04

CONDITION

USAGE

FUEL PRESSURE RELEASE

I FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line

TARGET IDLE RPM ADJ*

I IDLE CONDITION

When setting target idle speed

TARGET IGNITION TIMING ADJ*

I IDLE CONDITION

When adjusting target ignition timing After adjustment, confirm target ignition timing with a timing light.

*: This function is not necessary in the usual service procedure.

SELF DIAGNOSTIC MODE DTC and 1st Trip DTC

NCEC0034S05 NCEC0034S0501

Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX”, EC-QG-6.

Freeze Frame Data and 1st Trip Freeze Frame Data NCEC0034S0502 Freeze frame data item*

Description

DIAG TROUBLE CODE [PXXXX]

I Engine Control component part/control system has a trouble code, it is displayed as “PXXXX”. [Refer to “Alphabetical & P No. Index for DTC” (EC-QG-6).]

FUEL SYS DATA

I “Fuel injection system status” at the moment a malfunction is detected is displayed. I One mode in the following is displayed. “MODE 2”: Open loop due to detected system malfunction “MODE 3”: Open loop due to driving conditions (power enrichment, deceleration enrichment) “MODE 4”: Closed loop - using oxygen sensor(s) as feedback for fuel control “MODE 5”: Open loop - has not yet satisfied condition to go to closed loop

CAL/LD VALUE [%]

I The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] I The engine coolant temperature at the moment a malfunction is detected is displayed. or [°F] S-FUEL TRIM [%]

I “Short-term fuel trim” at the moment a malfunction is detected is displayed. I The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.

L-FUEL TRIM [%]

I “Long-term fuel trim” at the moment a malfunction is detected is displayed. I The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

ENGINE SPEED [rpm]

I The engine speed at the moment a malfunction is detected is displayed.

VHCL SPEED [km/h] or [mph]

I The vehicle speed at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

EC-58

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE CONSULT-II (Cont’d)

DATA MONITOR MODE Monitored item [Unit]

ECM input signals

Main signals

Description

NCEC0034S06

Remarks I Accuracy becomes poor if engine speed drops below the idle rpm. I If the signal is interrupted while the engine is running, an abnormal value may be indicated.

ENG SPEED [rpm]

q

q

I Indicates the engine speed computed from the POS signal of the crankshaft position sensor.

MAS A/F SE-B1 [V]

q

q

I The signal voltage of the mass air flow sensor is I When the engine is stopped, a displayed. certain value is indicated. I When the engine coolant temperature sensor is open or short-circuited, ECM enters failsafe mode. The engine coolant temperature determined by the ECM is displayed.

COOLAN TEMP/S [°C] or [°F]

q

q

I The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

HO2S1 (B1) [V]

q

q

I The signal voltage of the heated oxygen sensor 1 (front) is displayed.

HO2S2 (B1) [V]

q

I The signal voltage of the heated oxygen sensor 2 (rear) is displayed.

q

I Display of heated oxygen sensor 1 (front) signal during air-fuel ratio feedback control: RICH ... means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN ... means the mixture became “lean”, and control is being affected toward a rich mixture.

HO2S2 MNTR (B1) [RICH/LEAN]

q

I Display of heated oxygen sensor 2 (rear) signal: RICH ... means the amount of oxygen after I When the engine is stopped, a three way catalyst is relatively small. certain value is indicated. LEAN ... means the amount of oxygen after three way catalyst is relatively large.

VHCL SPEED SE [km/h] or [mph]

q

BATTERY VOLT [V]

q

THRTL POS SEN [V]

q

q

I The throttle position sensor signal voltage is displayed.

EGR TEMP SEN [V] (If so equipped)

q

q

I The signal voltage of the EGR temperature sensor is displayed.

INT/A TEMP SE [°C] or [°F]

q

START SIGNAL [ON/OFF]

q

q

I Indicates [ON/OFF] condition from the starter signal.

CLSD THL POS [ON/OFF]

q

q

I Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.

HO2S1 MNTR (B1) [RICH/LEAN]

q

I After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. I When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.

I The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed. I The power supply voltage of ECM is displayed.

I The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.

EC-59

I After starting the engine, [OFF] is displayed regardless of the starter signal.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

CONSULT-II (Cont’d) ECM input signals

Main signals

Description

AIR COND SIG [ON/OFF]

q

q

I Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioning signal.

P/N POSI SW [ON/OFF]

q

q

I Indicates [ON/OFF] condition from the PNP switch signal.

PW/ST SIGNAL [ON/OFF]

q

q

I Indicates [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure switch signal.

q

I Indicates [ON/OFF] condition from the electrical load signal and/or lighting switch. ON ... rear defogger is operating and/or lighting switch is on. OFF ... rear defogger is not operating and lighting switch is not on.

Monitored item [Unit]

LOAD SIGNAL [ON/OFF]

q

IGNITION SW [ON/OFF]

q

I Indicates [ON/OFF] condition from ignition switch.

HEATER FAN SW [ON/OFF]

q

I Indicates [ON/OFF] condition from the heater fan switch.

INJ PULSE-B1 [msec]

q

I Indicates the actual fuel injection pulse width compensated by ECM according to the input signals.

Remarks

I When the engine is stopped, a certain computed value is indicated.

I “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

B/FUEL SCHDL [msec] IGN TIMING [BTDC]

q

I Indicates the ignition timing computed by ECM according to the input signals.

IACV-AAC/V [step]

q

I Indicates the IACV-AAC valve control value computed by ECM according to the input signals.

A/F ALPHA-B1 [%]

q

I Indicates the mean value of the air-fuel ratio feedback correction factor per cycle.

AIR COND RLY [ON/OFF]

q

I Indicates the air conditioner relay control condition determined by ECM according to the input signals.

FUEL PUMP RLY [ON/OFF]

q

I Indicates the fuel pump relay control condition determined by ECM according to the input signals.

INT/V SOL-B1 [ON/OFF]

I The control condition of the valve timing solenoid valve (determined by ECM according to the input signal) is indicated. ON ... Intake valve timing control operating OFF ... Intake valve timing control not operating

COOLING FAN [ON/OFF]

I Indicates the control condition of the cooling fan determined by ECM according to the input signals. HI ... High speed operation LOW ... Low speed operation OFF ... Stop

q

EC-60

I When the engine is stopped, a certain value is indicated. I This data also includes the data for the air-fuel ratio learning control.

QG16I18DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II (Cont’d)

Monitored item [Unit]

EGR VOL CON/V [step] (If so equipped)

ECM input signals

Main signals

q

Description

Remarks

I Indicates the EGR volume control valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.

HO2S1 HTR (B1) [ON/OFF]

I Indicates [ON/OFF] condition of heated oxygen sensor 1 (front) heater determined by ECM according to the input signals.

HO2S2 HTR (B1) [ON/OFF]

I Indicates [ON/OFF] condition of heated oxygen sensor 2 (rear) heater determined by ECM according to the input signals.

PURG VOL C/V [%]

I Indicates the EVAP canister purge volume control solenoid valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.

CAL/LD VALUE [%]

I “Calculated load value” indicates the value of the current air flow divided by peak air flow.

ABSOL TH.P/S [%]

I “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.

MASS AIRFLOW [gm/s]

I Indicates the mass air flow computed by ECM according to the signal voltage of the mass air flow sensor.

TRVL AFTER MIL [km] or [Mile]

I Distance travelled while MI is activated

VOLTAGE [V]

I Voltage measured by the voltage probe.

PULSE [msec] or [Hz] or [%]

I Pulse width, frequency or duty cycle measured by the pulse probe.

IDL A/V LEAN

I Display the condition of idle air volume learning YET ... Idle air volume learning has not been performed yet. CMPLT ... Idle air volume learning has already been performed successfully. INCMP ... Idle air volume learning has not been performed successfully.

I Only “#” is displayed if item is unable to be measured. I Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.

NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-61

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

CONSULT-II (Cont’d)

DATA MONITOR (SPEC) MODE Monitored item [Unit]

MAS A/F SE-B1 [V]

ECM input signals

Main signals

q

q

Description

NLEC1365S07

Remarks

I The signal voltage of the mass air flow sen- I When the engine is running, specifisor specification is displayed. cation range is indicated.

B/FUEL SCHDL [msec]

I “Base fuel schedule” indicates the fuel injecI When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.

A/F ALPHA-B1 [%]

I When the engine is running, specifiI Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. I This data also includes the data for the air-fuel ratio learning control.

q

NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

ACTIVE TEST MODE TEST ITEM

CONDITION

NCEC0034S07

JUDGEMENT

CHECK ITEM (REMEDY)

I Engine: Return to the original I Harness and connector trouble condition If trouble symptom disappears, see FUEL INJECTION I Fuel injectors I Change the amount of fuel injec- CHECK ITEM. I Heated oxygen sensor 1 (front) tion using CONSULT-II.

IACV-AAC/V OPENING

I Engine: After warming up, idle the engine. I Change the IACV-AAC valve opening steps using CONSULTII.

Engine speed changes according to the opening steps.

ENG COOLANT TEMP

I Engine: Return to the original trouble condition I Change the engine coolant temperature indication using CONSULT-II.

I Harness and connector If trouble symptom disappears, see I Engine coolant temperature senCHECK ITEM. sor I Fuel injectors

I Engine: Return to the original trouble condition IGNITION TIMING I Timing light: Set I Retard the ignition timing using CONSULT-II.

I Harness and connector I IACV-AAC valve

I “Base Idle Air Volume Initializing” (Refer to EC-QG-33.) I Camshaft position sensor If trouble symptom disappears, see (PHASE) CHECK ITEM. I Crankshaft position sensor (POS) I Engine component parts and installing conditions

POWER BALANCE

I Engine: After warming up, idle the engine. I Air conditioner switch “OFF” I Shift lever “N” I Cut off each injector signal one at a time using CONSULT-II.

Engine runs rough or dies.

I I I I I I

COOLING FAN

I Ignition switch: ON I Turn the cooling fan “ON” and “OFF” using CONSULT-II.

Cooling fan moves and stops.

I Harness and connector I Cooling fan motor

FUEL PUMP RELAY

I Ignition switch: ON (Engine stopped) I Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.

Fuel pump relay makes the operat- I Harness and connector ing sound. I Fuel pump relay

EC-62

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE CONSULT-II (Cont’d)

TEST ITEM

CONDITION

JUDGEMENT

CHECK ITEM (REMEDY)

EGR VOL CONT/V (If so equipped)

I Engine: After warming up, idle the engine. Engine speed changes according I Change the EGR volume control to the opening step. valve opening step using CONSULT-II.

VALVE TIMING SOL

I Ignition switch: ON I Turn intake valve timing control solenoid valve “ON” and “OFF” using CONSULT-II and listen for operating sound.

SELF-LEARNING CONT

I In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching “CLEAR” on the screen.

PURG VOL CONT/V

I Engine: After warming up, idle the engine. I Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.

IDLE AIR VOL LEARN

I In this test, the idle air volume that keeps the engine within the specified range is memorised in ECM.

I Harness and connector I EGR volume control valve

I Harness and connector Intake valve timing control solenoid I Intake valve timing control solevalve makes an operating sound. noid valve

I Harness and connector I EVAP canister purge volume control solenoid valve

DTC & SRT CONFIRMATION MODE SRT STATUS Mode

NCEC0034S08 NCEC0034S0801

For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-QG-38.

SRT Work Support Mode This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

DTC Work Support Mode TEST MODE

TEST ITEM

CONDITION

NCEC0034S0802

REFERENCE PAGE

HO2S1 (B1) P0130

EC-QG-132

HEATED OXYGEN SEN- HO2S1 (B1) P0131 SOR 1 (FRONT) HO2S1 (B1) P0132

EC-QG-139 EC-QG-145

HO2S1 (B1) P0133

Refer to corresponding trouble diagnosis for DTC.

HO2S2 (B1) P0137 HEATED OXYGEN SENHO2S2 (B1) P0138 SOR 2 (REAR) HO2S2 (B1) P0139 EGR SYSTEM (If so equipped)

EC-QG-151 EC-QG-171 EC-QG-180 EC-QG-188

EGR SYSTEM P0400

EC-QG-244

EGR SYSTEM P1402

EC-QG-305

EC-63

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

CONSULT-II (Cont’d)

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NCEC0034S10

SEF705Y

SEF707X

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): I The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data...xx%” as shown at left, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If ‘STOP” is touched on the screen during “Recording Data ... xx%, “REALTIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): I DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. Use these triggers as follows: 1) “AUTO TRIG” I While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. I While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.) 2) “MANU TRIG” I If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

EC-64

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE CONSULT-II (Cont’d)

SEF720X

EC-65

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Generic Scan Tool (GST)

Generic Scan Tool (GST) DESCRIPTION

=NCEC0035 NCEC0035S01

Generic Scan Tool (OBDII scan tool) complying with ISO15031-4 has 9 different functions explained on the next page. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual.

SEF139P

GST INSPECTION PROCEDURE 1. 2.

NCEC0035S02

Turn ignition switch OFF. Connect “GST” to data link connector. (Data link connector is located under the fuse box cover.)

SEF922W

3. 4.

Turn ignition switch ON. Enter the program according to instruction on the screen or in the operation manual. (*: Regarding GST screens in this section, sample screens are shown.)

SEF398S

5.

Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.

SEF416S

EC-66

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

QG16I18DE

Generic Scan Tool (GST) (Cont’d)

FUNCTION Diagnostic test mode

NCEC0035S03

Function

MODE 1

READINESS TESTS

This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, distance traveled while MI is activated and system status information.

MODE 2

(FREEZE DATA)

This mode gains access to emission-related data value which were stored by ECM during the freeze frame. [For details, refer to “Freeze Frame Data” (EC-QG-58).]

MODE 3

DTCs

This mode gains access to emission-related power train trouble codes which were stored by ECM.

MODE 4

CLEAR DIAG INFO

This mode can clear all emission-related diagnostic information. This includes: I Clear number of diagnostic trouble codes (MODE 1) I Clear diagnostic trouble codes (MODE 3) I Clear trouble code for freeze frame data (MODE 1) I Clear freeze frame data (MODE 2) I Reset status of system monitoring test (MODE 1) I Clear on board monitoring test results (MODE 6 and 7)

MODE 6

(ON BOARD TESTS)

This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored.

MODE 7

(ON BOARD TESTS)

This mode enables the off board test drive to obtain test results for emission-related powertrain components/systems that are continuously monitored during normal driving conditions.

MODE 8 MODE 9

— (CALIBRATION ID)

This mode is not applicable on this vehicle. This mode enables the off-board (External test equipment) to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.

EC-67

TROUBLE DIAGNOSIS — INTRODUCTION

QG16I18DE

Introduction

Introduction

MEF036D

SEF233G

NCEC0036

The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow” on EC-QG-70. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle.

SEF234G

DIAGNOSTIC WORKSHEET KEY POINTS WHAT

üü..... Vehicle & engine model WHEN ..... Date, Frequencies WHERE ..... Road conditions HOW ..... Operating conditions, Weather conditions, Symptoms SEF907L

NCEC0036S01

There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. Some conditions may cause the malfunction indicator to come on steady or blink and DTC to be detected. Example: Vehicle ran out of fuel, which caused the engine to misfire.

EC-68

TROUBLE DIAGNOSIS — INTRODUCTION

QG16I18DE Introduction (Cont’d)

Worksheet Sample

NCEC0036S0101

MTBL0311

EC-69

TROUBLE DIAGNOSIS — INTRODUCTION

QG16I18DE

Work Flow

Work Flow

NCEC0037

SEF510ZD

*1: If the incident cannot be duplicated, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-QG-103.

*3: If time data of “SELF-DIAG RESULTS” is other than “0” or “1t” refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *4: If the malfunctioning part cannot

EC-70

be found, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. *5: EC-QG-81 *6: EC-QG-40 *7: EC-QG-98

TROUBLE DIAGNOSIS — INTRODUCTION

QG16I18DE Work Flow (Cont’d)

DESCRIPTION FOR WORK FLOW STEP

NCEC0037S01

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-QG-69.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II or Generic Scan Tool) the (1st trip) Diagnostic Trouble Code (DTC) and the (1st trip) freeze frame data, then erase the code and the data. (Refer to EC-QG-44.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. See EC-QG-82.) Also check related service bulletins for information.

STEP III

Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the (1st trip) Diagnostic Trouble Code by driving in (or performing) the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or Generic Scan Tool. During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) In case the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the (1st trip) DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX. If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-QG-72.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS-SPECIFICATION VALUE”, EC-QG-98. (If malfunction is detected, proceed to “REPAIR/REPLACE”. Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-QG-82.)

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-QG-91. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”). Repair or replace the malfunction parts.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” and confirm the normal code [Diagnostic trouble code No. P0000 or 0000] is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM. (Refer to EC-QG-44.)

EC-71

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE

Basic Inspection

Basic Inspection

NCEC0038

Precaution: Perform Basic Inspection without electrical or mechanical loads applied; I Headlamp switch is OFF, On vehicle equipped with daytime light system, set lighting switch to the 1st position to light only small lamps. I Air conditioner switch is OFF, I Rear window defogger switch is OFF, I Steering wheel is in the straight-ahead position, etc. 1

INSPECTION START

1. Check service records for any recent repairs that may indicate a related problem, or a current need for scheduled maintenance. 2. Open engine hood and check the following: I Harness connectors for improper connections I Vacuum hoses for splits, kinks and improper connections I Wiring for improper connections, pinches and cuts I Air cleaner clogging I Hoses and ducts for leaks

SEF983U

©

2

GO TO 2.

CHECK THROTTLE DRUM OPERATION-I

Confirm that throttle drum is in contact with the stopper. OK or NG OK (with CONSULT-II)

©

GO TO 5.

OK (without CONSULTII)

©

GO TO 8.

NG

©

GO TO 3.

3

CHECK ACCELERATOR WIRE INSTALLATION

Check accelerator wire for slack OK or NG OK

©

GO TO 4.

NG

©

Adjust accelerator wire. Refer to FE section, “Adjusting Accelerator Wire”.

EC-72

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE Basic Inspection (Cont’d)

4

CHECK THROTTLE VALVE OPERATION

1. Remove intake air ducts. 2. Check throttle valve operation when moving throttle drum by hand. OK or NG OK

©

Retighten the throttle drum fixing nuts.

NG

©

Clean the throttle body and throttle valve.

5 1. 2. 3. 4. 5.

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Select “THRTL POS SEN” and “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. Make sure that “THRTL POS SEN” indicates 0.35 to 0.65V, and “CLSD THL POS” indicates “ON”. (Accelerator pedal is fully released.)

NEF238A

OK or NG OK

©

GO TO 11.

NG

©

GO TO 6.

6

ADJUST THROTTLE POSITION SENSOR IDLE POSITION

With CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until “THRTL POS SEN” indication becomes 0.35 to 0.65V.

SEF964W

3. Tighten the throttle position sensor fixing bolts. ©

GO TO 7.

EC-73

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE

Basic Inspection (Cont’d)

7

RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY

With CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle position memory will not be reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Select “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. 3. Stop engine. (Turn ignition switch “OFF”.) 4. Turn ignition switch “ON” and wait at least 5 seconds.

SEF864V

5. Turn ignition switch “OFF” and wait at least 9 seconds. 6. Repeat steps 4 and 6 until “CLSD THL POS” indication changes to “ON”.

SEF061Y

©

8 1. 2. 3. 4.

GO TO 11.

CHECK CLOSED THROTTLE POSITION SWITCH IDLE POSITION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Check voltage between ECM terminal 92 and ground with accelerator pedal fully released.

NEF239A

Voltage: 0.35 to 0.65V OK

©

GO TO 6.

NG

©

GO TO 9.

EC-74

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE Basic Inspection (Cont’d)

9

ADJUST THROTTLE POSITION SENSOR IDLE POSITION

Without CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until the voltage between ECM terminal 92 and ground becomes 0.35 to 0.65V.

SEF964W

3. Tighten the throttle position sensor fixing bolts. ©

10

GO TO 10.

RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY

Without CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle position memory will not be reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. (Turn ignition switch “OFF”.) 3. Turn ignition switch “ON” and wait at least 5 seconds.

SEF864V

4. Turn ignition switch “OFF” and wait at least 9 seconds. 5. Repeat steps 4 and 6, 20 times. ©

11

GO TO 11.

CHECK (1ST TRIP) DTC

1. Start engine and warm it up to normal operating temperature. 2. Rev (2,000 to 3,000 rpm) two or three times. 3. Make sure no (1st trip) DTC is displayed with CONSULT-II GST or Diagnostic Test Mode II (Self-diagnostic Results). OK or NG OK

©

GO TO 13.

NG

©

GO TO 12.

12

REPAIR MALFUNCTION

Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. ©

GO TO 11.

EC-75

TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d)

13

CHECK TARGET IDLE SPEED

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK

©

GO TO 22.

NG

©

GO TO 14.

14

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 15.

INCMP

©

1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.

15

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK

©

GO TO 20.

NG

©

GO TO 16.

16

REPLACE IACV-AAC VALVE

Replace IACV-AAC valve. ©

17

GO TO 17.

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 18.

INCMP

©

1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.

EC-76

QG16I18DE

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE Basic Inspection (Cont’d)

18

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK

©

GO TO 20.

NG

©

GO TO 19.

19

CHECK ECM FUNCTION

1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-QG-45. ©

20

GO TO 14.

CHECK IGNITION TIMING

1. Start engine and warm it up to normal operating temperature. 2. Check ignition timing at idle using a timing light.

SEM872F

Ignition timing: 8°±5° BTDC

OK

©

GO TO 28.

NG

©

GO TO 21.

21

CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM section. OK or NG OK

©

GO TO 19.

NG

©

1. Repair the timing chain installation. 2. GO TO 14.

EC-77

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE

Basic Inspection (Cont’d)

22

CHECK IGNITION TIMING

1. Start engine and let it idle. 2. Check ignition timing at idle using a timing light.

SEM872F

Ignition timing: 8°±5° BTDC

OK

©

GO TO 28.

NG

©

GO TO 23.

23

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 24.

INCMP

©

1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 23.

24

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode With CONSULT-II. 3. Check idle speed. 700±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 700±50 rpm OK or NG OK

©

GO TO 26.

NG

©

GO TO 25.

25

CHECK ECM FUNCTION

1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-QG-45. ©

GO TO 23.

EC-78

TROUBLE DIAGNOSIS — BASIC INSPECTION

QG16I18DE Basic Inspection (Cont’d)

26

CHECK IGNITION TIMING AGAIN

Check ignition timing again. Refer to Test No. 22.

OK

©

GO TO 28.

NG

©

GO TO 27.

27

CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM section. OK or NG OK

©

GO TO 25.

NG

©

1. Repair the timing chain installation. 2. GO TO 23.

28

ERASE UNNECESSARY DTC

After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-QG-44. ©

INSPECTION END

EC-79

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

DTC Inspection Priority Chart

DTC Inspection Priority Chart

NCEC0039

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority

Detected items (DTC)

1

I I I I I I I I I I I

P0100 Mass air flow sensor P0110 Intake air temperature sensor P0115 Engine coolant temperature sensor P0120 Throttle position sensor P0325 Knock sensor P0340 Camshaft position sensor (PHASE) circuit P0403 EGR volume control valve* P0500 Vehicle speed sensor P0605 ECM P0335, P1336 Crankshaft position sensor (POS) P1706 Park/Neutral position switch

2

I I I I I I I

P0130 P0135 P0137 P0141 P0443 P1217 P1401

3

I I I I I I

P0171, P0172 Fuel injection system function P0300 - P0304 Misfire P0400, P1402 EGR function* P0420 Three way catalyst function P0505 IACV-AAC valve P1111 Intake valve timing control

- P0134 Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) - P0140 Heated oxygen sensor 2 (rear) Heated oxygen sensor 2 heater (rear) EVAP canister purge volume control solenoid valve Overheat (cooling system) EGR temperature sensor*

*: If so equipped

EC-80

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE Fail-safe Chart

Fail-safe Chart

=NCEC0040

The ECM enters fail-safe mode if any of the following malfunctions is detected due to the open or short circuit. When the ECM enters the fail-safe mode, the MI illuminates. DTC No. CONSULT-II GST

ECM*1

P0100

0100

Mass air flow sensor circuit

P0115

0115

Engine coolant tempera- Engine coolant temperature will be determined by ECM based on the time ture sensor circuit after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. The radiator fan operates.

Detected items

Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

Condition Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or Start

80°C (176°F)

Except as shown above P0120

0120

Throttle position sensor circuit

When engine is idling When accelerating Unable to access Diagnostic Test Mode II

ECM

40 - 80°C (104 - 176°F) (Depends on the time)

Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor. Condition

Unable to access ECM

Engine coolant temperature decided (CONSULT-II display)

Driving condition Normal Poor acceleration

ECM fail-safe activating condition The computing function of the ECM was judged to be malfunctioning. When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in the CPU of ECM), the MI on the instrument panel lights to warn the driver. However it is not possible to access ECM and DTC cannot be confirmed. Engine control with fail-safe When ECM fail-safe is operating, fuel injection, ignition timing, fuel pump operation and IACV-AAC valve operation are controlled under certain limitations. ECM fail-safe operation Engine speed

Engine speed will not rise more than 3,000 rpm

Fuel injection

Simultaneous multiport fuel injection system

Ignition timing

Ignition timing is fixed at the preset valve

Fuel pump

Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls

IACV-AAC valve

Full open

Replace ECM, if ECM fail-safe condition is confirmed. *: In Diagnostic Test Mode II (Self-diagnostic results)

EC-81

QG16I18DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart

Symptom Matrix Chart

NCEC0041

SYSTEM — ENGINE CONTROL SYSTEM

NCEC0041S01

Fuel pump circuit

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Positive crankcase ventilation system

3

3

4

4

4

Incorrect idle speed adjustment

3

3

IACV-AAC valve circuit

1

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

Ignition circuit

1

1

2

2 2

Main power supply and ground circuit Air conditioner circuit

Fuel

Air

Ignition

EGR*

AJ

AK

AL

2

2

4

4

2

2

4

4

4

4

4

1 2

AM HA

3

EC-QG-336

2

EC-QG-319

4

4

EC-QG-25

4

4

4

1

1

1

1

2

2

2

2

1

1

1

1

EC-QG-32

2

2

2

2

2

EC-QG-323

2

3

3

3

EC-QG-252

1

2

3

3

3

EC-QG-244, 252, 305

2

2

3

3

3

2

2

3

3

3

EC-82

3

3

2

2

3

3

3

3

4

2

EC-QG-30

1 - 6: The numbers refer to the order of inspection. (continued on next page) *: If so equipped

4

Reference page

4

EGR volume control valve circuit EGR system

AG AH

BATTERY DEAD (UNDER CHARGE)

AF

EXCESSIVE OIL CONSUMPTION

HIGH IDLE/LOW IDLE

AE

EXCESSIVE FUEL CONSUMPTION

LACK OF POWER/POOR ACCELERATION

AD

OVERHEATS/WATER TEMPERATURE HIGH

SPARK KNOCK/DETONATION

AC

SLOW/NO RETURN TO IDLE

HESITATION/SURGING/FLAT SPOT

AB

IDLING VIBRATION

ENGINE STALL

AA

Warranty symptom code

ROUGH IDLE/HUNTING

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

3 2 3

1

EC-QG-28 EC-QG-32 2

EC-QG-274

3

2

EC-QG-103

3

2

HA section

QG16I18DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Symptom Matrix Chart (Cont’d)

HESITATION/SURGING/FLAT SPOT

SPARK KNOCK/DETONATION

LACK OF POWER/POOR ACCELERATION

HIGH IDLE/LOW IDLE

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

AB

AC

AD

AE

AF

AG

AH

AJ

AK

AL

Crankshaft position sensor (POS) circuit

2

2

Camshaft position sensor (PHASE) circuit

3

2

Mass air flow sensor circuit

1

1

2

2

2

2

1

2

3

2

1

2

3

2

Throttle position sensor circuit

1

2

Incorrect throttle position sensor adjustment

3

Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit

2

Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit

1

Knock sensor circuit 2

Start signal circuit

2

2

AM HA

3

EC-QG-238

2

2

EC-QG-110

2

2

2

EC-QG-132

3

2

2

3

2

EC-QG-120

2

2

2

2

2

2

EC-QG-125

1

1

1

1

1

1

1

EC-QG-72

3

3

3

EC-QG-267

3

EC-QG-228

3

EC-QG-282, 81

3

3

3

3

3

3

3

3

EC-QG-332

PNP switch circuit Power steering oil pressure switch circuit

Reference page

EC-QG-232

2

ECM

BATTERY DEAD (UNDER CHARGE)

ENGINE STALL

AA

Warranty symptom code

EXCESSIVE OIL CONSUMPTION

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

3

3

2

Electrical load signal circuit 1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-83

3

3

3

EC-QG-313

3

3

EC-QG-342

3

3

EC-QG-351

QG16I18DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d)

SYSTEM — ENGINE MECHANICAL & OTHER

NCEC0041S03

Fuel

AG AH

AJ

AK

AL

BATTERY DEAD (UNDER CHARGE)

AF

EXCESSIVE OIL CONSUMPTION

AE

EXCESSIVE FUEL CONSUMPTION

HIGH IDLE/LOW IDLE

AD

OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION

AC

SLOW/NO RETURN TO IDLE

SPARK KNOCK/DETONATION

AB

IDLING VIBRATION

HESITATION/SURGING/FLAT SPOT

AA

ROUGH IDLE/HUNTING

ENGINE STALL

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

AM HA

Fuel tank

FE section 5

Fuel piping Vapor lock

5

5

5

5

5

5

5

5

5

5

5

5

5

Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air

5

—

Air duct Air cleaner Air leakage from air duct (Mass air flow sensor — throttle body) Throttle body, Throttle wire

5

5

5

5 5

5

5

5

5 5

FE section

Air leakage from intake manifold/ Collector/Gasket Cranking

—

Battery 1

1

1

1

1

1

1

Alternator circuit

EL section 1

Starter circuit

3

Flywheel

6

EM section

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-84

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

Symptom Matrix Chart (Cont’d)

5

5

5

5

5

AG AH

AJ

AK

AL

BATTERY DEAD (UNDER CHARGE)

AF

EXCESSIVE OIL CONSUMPTION

AE

EXCESSIVE FUEL CONSUMPTION

AD

OVERHEATS/WATER TEMPERATURE HIGH

HIGH IDLE/LOW IDLE

AC

SLOW/NO RETURN TO IDLE

LACK OF POWER/POOR ACCELERATION

AB

IDLING VIBRATION

SPARK KNOCK/DETONATION

AA

ROUGH IDLE/HUNTING

HESITATION/SURGING/FLAT SPOT

Engine

ENGINE STALL

Warranty symptom code

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

AM HA

Cylinder head 5

5

5

Cylinder head gasket

4

3

Cylinder block Piston

4 EM section

Piston ring 6

6

6

6

6

6

6

6

5

5

5

5

5

5

5

5

Connecting rod Bearing Crankshaft Valve mechanism

Timing chain Camshaft EM section

Intake valve 3 Exhaust valve Exhaust

Exhaust manifold/Tube/Muffler/ Gasket

5

5

5

5

5

5

5

5

FE section

5

5

5

5

5

5

5

5

MA, EM and LC sections

Three way catalyst Lubrication

Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery Oil level (Low)/Filthy oil

Cooling

Radiator/Hose/Radiator filler cap Thermostat

5

LC section

Water pump Water gallery

5

5

5

5

5

Cooling fan

5

5

4 5

Coolant level (low)/ Contaminated coolant

5 EC-QG-289 MA section

1 - 6: The numbers refer to the order of inspection.

EC-85

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0042

Remarks: I Specification data are reference values. I Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. (i.e., Adjust ignition timing with a timing light before monitoring IGN TIMING. Specification data might be displayed even when ignition timing is not adjusted to specification. This IGN TIMING monitors the data calculated by the ECM according to the input signals from the camshaft position sensor and other ignition timing related sensors.) I If the real-time diagnosis results are NG, and the on board diagnostic system results are OK, when diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal. MONITOR ITEM

CONDITION

ENG SPEED

I Tachometer: Connect I Run engine and compare tachometer indication with the CONSULT-II value.

MAS A/F SE-B1

I I I I

COOLAN TEMP/S

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

HO2S2 (B1) HO2S2 MNTR (B1)

Almost the same speed as the CONSULT-II value.

Idle

1.0 - 1.7V

2,500 rpm

1.5 - 2.1V

I Engine: After warming up

More than 70°C (158°F) 0 - 0.3V +, 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

SPECIFICATION

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

I Engine: After warming up

Revving engine from idle to 3,000 rpm quickly

0 - 0.3V +, 0.6 - 1.0V LEAN +, RICH

VHCL SPEED SE

I Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the CONSULT-II value

BATTERY VOLT

I Ignition switch: ON (Engine stopped)

11 - 14V

I Engine: Idle

Throttle valve fully closed

0.35 - 0.65V

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

3.7 - 4.5V

THRTL POS SEN

EGR TEMP SEN*

I Engine: After warming up

Less than 4.5V

START SIGNAL

I Ignition switch: ON , START , ON

OFF , ON , OFF

I Engine: Idle

Throttle valve: Idle position

ON

I Ignition switch: ON (Engine stopped)

Throttle valve: Slightly open

OFF

A/C switch “OFF”

OFF

A/C switch “ON” (Compressor operates)

ON

Shift lever “N”

ON

Except above

OFF

Steering wheel in neutral position (forward direction)

OFF

The steering wheel is turned

ON

CLSD THL/P SW CLSD THL POS

AIR COND SIG

P/N POSI SW

PW/ST SIGNAL

IGNITION SW

I Engine: After warming up, idle the engine

I Ignition switch: ON

I Engine: After warming up, idle the engine I Ignition switch: ON , OFF

ON , OFF

*: If so equipped

EC-86

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

INJ PULSE-B1

LOAD SIGNAL

B/FUEL SCHDL

IGN TIMING

IACV-AAC/V

PURG VOL C/V

CONDITION I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

I Engine: running

SPECIFICATION

Idle

2.4 - 3.2 msec

2,000 rpm

1.9 - 3.2 msec

Rear window defogger or headlamp “ON”

ON

Except the above

OFF

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

1.5 - 2.5 msec

2,000 rpm

1.5 - 2.5 msec

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

8° BTDC

2,000 rpm

Approx. 30° BTDC

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

5 - 20 steps

2,000 rpm

—

Idle

0%

Rev engine up from 2,000 to 4,000 rpm.

—

Maintaining engine speed at 2,000 rpm

75 - 125%

I Engine: After warming up I No-load I M/T models: Lift up drive wheels and shift to 1st gear position.

A/F ALPHA-B1

I Engine: After warming up

AIR COND RLY

I Air conditioner switch: OFF , ON

OFF , ON ON

FUEL PUMP RLY

I Ignition switch is turned to ON (Operates for 1 second) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds) I Except as shown above

OFF

COOLING FAN

HO2S1 HTR (B1)

HO2S2 HTR (B1)

I After warming up engine, idle the engine. I Air conditioner switch: OFF

Engine coolant temperature is 99°C (210°F) or less

OFF

Engine coolant temperature is 100°C (212°F) or more

ON

I Engine speed: Below 3,200 rpm

ON

I Engine speed: Above 3,200 rpm

OFF

I Engine speed

Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

Above 3,600 rpm

OFF

I Ignition switch ON (Engine stopped) Idle INT/V SOL-B1

I Engine: After warming up

EGR VOL CON/V*

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

OFF OFF

Revving engine with full throttle openON ing (Under 4,600 rpm) Idle

0 step

Revving engine up to 3,000 rpm quickly

10 - 55 steps

*: If so equipped

EC-87

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM HEATER FAN SW

CAL/LD VALUE

ABSOL TH⋅P/S

MASS AIRFLOW

IDL A/V LEARN

TRVL AFTER MIL

CONDITION

SPECIFICATION

I Heater fan switch is “ON”

ON

I Heater fan switch is “OFF’

OFF

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

Not used

2,500 rpm

Not used

I Engine: Idle

Throttle valve fully closed

0.0°

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

Approx. 80°

Idle

1.0 - 4.0 g⋅m/s

2,500 rpm

5.0 - 10.0 g⋅m/s

IDLE AIR VOL LEARN in ACTIVE TEST has not been performed

YET

IDLE AIR VOL LEARN in ACTIVE TEST has already been performed successfully

CMPLT

IDLE AIR VOL LEARN in ACTIVE TEST has not been performed successfully

INCMP

Vehicle has traveled after MI has turned ON.

0 - 65,535 km (0 - 40,722 mile)

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: N No-load

I Ignition switch: ON

I Ignition switch: ON

Major Sensor Reference Graph in Data Monitor Mode

NCEC0043

The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)

THRTL POS SEN, ABSOL TH⋅P/S, CLSD THL POS

NCEC0043S01

Below is the data for “THRTL POS SEN”, “ABSOL TH⋅P/S” and “CLSD THL POS” when depressing the accelerator pedal with the ignition switch “ON”. The signal of “THRTL POS SEN” and “ABSOL TH⋅P/S” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. CLSD THL POS 10:22 OFF

-00"09 +02"69 ON

ABSOL TH P/S 10:22 % 0

25

50

-00"09 +02"69 75

100

THRTL POS SEN 10:22 x0.1V 0

13

26

-00"09 +02"69 38

51

Full Release

Full Depress SEF580W

ENG SPEED, MAS A/F SE-B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1

NCEC0043S02

Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL POS SEN”, “HO2S1 (B1)”, “HO2S2 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine to normal operating temperature. Each value is for reference, the exact value may vary.

EC-88

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

● “ENG SPEED” should increase gradually while

ENG SPEED

depressing the accelerator pedal and should decrease gradually after releasing the pedal without any intermittent drop.

● “MAS A/F SE-B1” should increase when

MAS A/F SE-B1

depressing the accelerator pedal and should decrease at the moment “THRTL POS SEN” is closed (accelerator pedal is released).

NEF066A

EC-89

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

SEF601Y

SEF170YA

EC-90

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value

ECM Terminals and Reference Value PREPARATION 1. 2.

NCEC0044 NCEC0044S01

ECM is located behind the center console. For this inspection: Remove the front passenger center console panel. Remove ECM harness protector.

SEF967W

3. I I I

Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily. Open harness securing clip to make testing easier. Use extreme care not to touch 2 pins at one time. Data is for comparison and may not be exact.

SEF367I

ECM HARNESS CONNECTOR TERMINAL LAYOUTNCEC0044S02

SEF970W

ECM INSPECTION TABLE

NCEC0044S03

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

EC-91

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

1

3

4

WIRE COLOR

Y/R

W/R

L

ITEM

Intake valve timing control solenoid valve

Heated oxygen sensor 2 heater (rear)

Heated oxygen sensor 1 heater (front)

CONDITION

DATA (DC Voltage)

[Engine is running] I Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Lift up drive wheels and shift gear “ON” I Rev engine up from 1,200 to 3,000 rpm

Approximately 0V

[Engine is running] I Engine speed is below 3,600 rpm I After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

Approximately 0.7V

[Ignition switch “ON”] I Engine stopped I Engine speed is above 3,600 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Engine speed is below 3,200 rpm

Approximately 0V

[Engine is running] I Engine speed is above 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

6 7 15 16

BR Y/B P OR

IACV-AAC valve

[Engine is running] I Warm-up condition I Idle speed

0.1 - 14V

8* 9* 17* 18*

W/B SB G/R R/Y

EGR volume control valve

[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm

0 - 14V

[Engine is running] I Cooling fan is not operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Cooling fan is operating

Approximately 0V

13

LG/R

Cooling fan relay

5 - 12V

14

P/B

EVAP canister purge volume control valve (ON/OFF duty)

[Engine is running] I Warm-up condition I Accelerator pedal depressed

SEF975W

[Ignition switch “ON”] I For 1 second after turning ignition switch “ON” [Engine is running] 21

B/P

0 - 1V

Fuel pump relay [Ignition switch “ON”] BATTERY VOLTAGE I More than 1 second after turning ignition switch (11 - 14V) “ON”

22

23

OR/L

L/W

Malfunction indicator

Air conditioner relay

[Ignition switch “ON”]

0 - 1V

[Engine is running] I Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Both A/C switch and blower switch are “ON”

Approximately 0V

[Engine is running] I A/C switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

*: If so equipped

EC-92

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

31

WIRE COLOR

W/G

ITEM

CONDITION

ECM relay (Self shutoff)

DATA (DC Voltage)

[Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”

0 - 1V

[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”

BATTERY VOLTAGE (11 - 14V) 10 - 11V

[Engine is running] I Warm-up condition I Idle speed

SEF973W

32

L/OR

Tachometer 10 - 11V

[Engine is running] I Engine speed is 2,000 rpm

SEF974W

0 - 0.3V

[Engine is running] I Warm-up condition I Idle speed 35 36 37 38

Y/G PU/G L/Y GY/L

Ignition Ignition Ignition Ignition

signal signal signal signal

(No. (No. (No. (No.

1) 2) 3) 4)

SEF971W

0.2 - 0.4V

[Engine is running] I Engine speed is 2,000 rpm

SEF972W

41

42

43

B/Y

G/OR

B/R

[Ignition switch “ON”]

Approximately 0V

[Ignition switch “START”]

9 - 12V

[Ignition switch “ON”] I Gear position is “Neutral position”

Approximately 0V

[Ignition switch “ON”] I Except the above gear position

Approximately 5V

[Ignition switch “OFF”]

0V

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

Start signal

PNP switch

Ignition switch

EC-93

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

44

46

48

50

WIRE COLOR

GY

PU/W

B

R

ITEM

Air conditioner switch

Power steering oil pressure switch

ECM ground

Electrical load signal (Headlamp Rear defogger)

CONDITION

DATA (DC Voltage)

[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)

Approximately 0V

[Engine is running] I Air conditioner switch is “OFF”

Approximately 5V

[Engine is running] I Steering wheel is fully turned

Approximately 0V

[Engine is running] I Steering wheel is not turned

Approximately 5V

[Engine is running] I Idle speed

Engine ground

[Engine is running] I Headlamp switch or rear defogger switch is “ON”

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Headlamp switch and rear defogger switch are “OFF”

Approximately 0V

51

LG/B

Blower fan SW

[Ignition switch “ON”] I Blower fan switch is “ON”

Approximately 0V

57

B

ECM ground

[Engine is running] I Idle speed

Engine ground

58

B

Sensors’ ground

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

[Engine is running] I Warm-up condition I Idle speed

1.0 - 1.7V

[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm

1.5 - 2.1V

61

B

Mass air flow sensor

0 - Approximately 0.7V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF008W

63

L

Heated oxygen sensor 2 (rear)

[Engine is running] I After warming up to normal operating temperature and engine speed is 3,000 rpm

0 - Approximately 1.0V

64

G

Intake air temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with intake air temperature

EC-94

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 2.0 - 3.0V

[Engine is running] I Warm-up condition I Idle speed

66* 75

W W

SEF977W

Camshaft position sensor (PHASE)

2.0 - 3.0V

[Engine is running] I Engine speed is 2,000 rpm

SEF978W

67

W/L

Power supply for ECM (Back-up)

[Ignition switch “OFF”]

BATTERY VOLTAGE (11 - 14V)

70

BR/Y

Engine coolant temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with engine coolant temperature

[Engine is running] I Warm-up condition I Idle speed

Less than 4.5V

[Engine is running] I Warm-up condition I EGR system is operating

0 - 1.0V

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

[Engine is running] I Air conditioner switch is “ON” (Compressor operates)

More than 1.5V

[Engine is running] I Air conditioner switch is turned from “ON” to “OFF”

Voltage is decreasing gradually

[Engine is running] I Idle speed

1.0 - 4.0V

72*

73

74

81

PU

W

R/L

W

EGR temperature sensor

Mass air flow sensor ground

Refrigerant pressure sensor

Knock sensor

*: If so equipped

EC-95

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 3.0 - 4.0V

[Engine is running] I Warm-up condition I Idle speed

85

W

SEF979W

Crankshaft position sensor (POS)

3.0 - 4.0V

[Engine is running] I Engine speed is 2,000 rpm

SEF980W

2.0 - 3.0V

86

OR/W

[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W

92

93

Y

G/R

Throttle position sensor

Data link connector

[Engine is running] I Accelerator pedal released

0.35 - 0.65V

[Ignition switch “ON”] I Accelerator pedal fully depressed

3.7 - 4.5V

[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)

Approximately 0V BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Idle speed 101 103 105 107

R/B Y/B G/B L/B

Injector Injector Injector Injector

No. No. No. No.

1 2 3 4

SEF011W

BATTERY VOLTAGE (11 - 14V) [Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF012W

106 108

B/Y

ECM ground

[Engine is running] I Idle speed

EC-96

Engine ground

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

QG16I18DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

110 112

R R

Power supply for ECM

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

111

G

Sensors’ power supply

[Ignition switch “ON”]

Approximately 5V

114

G/W

Adjust switch

[Engine is running] I Idle speed

0V

115

BR/W

Data link connector

[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)

0 - 10V

116

Refer to EL section

Immobilizer

[Engine is running] I Idle speed (GST is disconnected)

BATTERY VOLTAGE (11 - 14V)

EC-97

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

QG16I18DE

Description

Description

NLEC1748

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the MIL. The SP value will be displayed for the following three items: I B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) I A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) I MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition

NLEC1749

I Vehicle driven distance: More than 5,000 km (3,107 miles) I Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2, 14.25 - 15.12 psi) I Atmospheric temperature: 20 - 30°C (68 - 86°F) I Engine coolant temperature: 75 - 95°C (167 - 203°F) I Transmission: Warmed-up*1 I Electrical load: Not applied*2 I Engine speed: Idle *1: For after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (CVT fluid temperature sensor signal) indicates less than 0.9V. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Cooling fans are not operating. Steering wheel is straight ahead.

Inspection Procedure

SEF601Z

NLEC1750

NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-QG-72. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to “Diagnostic Procedure”, EC-QG-99.

EC-98

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

QG16I18DE Diagnostic Procedure

Diagnostic Procedure

NLEC1751

SEF613ZA

EC-99

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

QG16I18DE

Diagnostic Procedure (Cont’d)

SEF768Z

EC-100

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

QG16I18DE

Diagnostic Procedure (Cont’d)

SEF615Z

EC-101

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT QG16I18DE Description

Description

NCEC0045

Intermittent incidents (I/I) may occur. In many cases, the problem resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer’s complaint often do not recur on DTC (1st trip) visits. Realize also that the most frequent cause of I/I occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the specific problem area.

COMMON I/I REPORT SITUATIONS

NCEC0045S01

STEP in Work Flow

Situation

II

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “1t”.

III

The symptom described by the customer does not recur.

IV

(1st trip) DTC data does not appear during the DTC CONFIRMATION PROCEDURE.

VI

The TROUBLE DIAGNOSIS for PXXXX does not indicate the problem area.

Diagnostic Procedure 1

INSPECTION START

Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION-RELATED INFORMATION” (EC-QG-44).

©

2

GO TO 2.

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION” in GI section. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

3

SEARCH FOR ELECTRICAL INCIDENT

Perform “Incident Simulation Tests” in GI section. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK CONNECTOR TERMINALS

Refer to “How to Check Enlarged Contact Spring of Terminal” in GI section. OK or NG OK

©

INSPECTION END

NG

©

Repair or replace connector.

EC-102

NCEC0046

QG16I18DE

TROUBLE DIAGNOSIS FOR POWER SUPPLY

Main Power Supply and Ground Circuit

Main Power Supply and Ground Circuit WIRING DIAGRAM

NCEC0047

BATTERY

Refer to EL-POWER.

ST

OFF

ACC

IGNITION SWITCH

ON

ECM RELAY

FUSE BLOCK (J/B)

To EC-IGN/SG, EC-TP/SW, EC-AAC/V, EC-EGR, EC-EGVC/V

ECM

: Detectable line for DTC : Non-detectable line for DTC

Refer to last page (Foldout page)

YEC770

EC-103

QG16I18DE

TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d)

ECM TERMINALS AND REFERENCE VALUE

NCEC0048

Specification data are reference values and are measured between each terminal and ECM. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

31

43

WIRE COLOR

W/G

B/R

ITEM

ECM relay (Self shut-off)

CONDITION

DATA (DC Voltage)

[Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”

0 - 1V

[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “OFF”]

0V

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

Ignition switch

48

B

ECM ground

[Engine is running] I Idle speed

Engine ground

57

B

ECM ground

[Engine is running] I Idle speed

Engine ground

67

W/L

Power supply for ECM (Back-up)

[Ignition switch “OFF”]

BATTERY VOLTAGE (11 - 14V)

106 108

B/Y B/Y

ECM ground

[Engine is running] I Idle speed

Engine ground

110 112

R R

Power supply for ECM

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

DIAGNOSTIC PROCEDURE 1

INSPECTION START

Start engine. Is engine running? Yes or No Yes

©

GO TO 9.

No

©

GO TO 2.

EC-104

NCEC0049

TROUBLE DIAGNOSIS FOR POWER SUPPLY

QG16I18DE

Main Power Supply and Ground Circuit (Cont’d)

2

CHECK POWER SUPPLY-I

1. Turn ignition switch “OFF” and then “ON”. 2. Check voltage between ECM terminal 43 and ground with CONSULT-II or tester.

Voltage: Battery voltage

SEF981W

OK or NG OK

©

GO TO 9.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. I 10A Fuse I 40A fusible link I Harness connectors M50, F104 I Harness for open or short between ECM and fuse block I Harness for open or short between fuse block and ignition switch ©

4

Repair harness or connectors.

CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to power in harness or connectors.

EC-105

TROUBLE DIAGNOSIS FOR POWER SUPPLY

QG16I18DE

Main Power Supply and Ground Circuit (Cont’d)

5

CHECK POWER SUPPLY-II

1. Disconnect ECM relay.

SEF984W

2. Check voltage between ECM relay terminals 1, 6 and ground with CONSULT-II or tester.

SEF101Y

OK or NG OK

©

GO TO 7.

NG

©

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. I 10A fuse I 15A fuse I Harness for open or short between ECM relay and battery ©

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Check harness continuity between ECM terminal 31 and ECM relay terminal 2. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

Go to “IGNITION SIGNAL”, EC-QG-323.

NG

©

GO TO 8.

8

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM relay and ECM. ©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-106

TROUBLE DIAGNOSIS FOR POWER SUPPLY

QG16I18DE

Main Power Supply and Ground Circuit (Cont’d)

9

CHECK POWER SUPPLY-II

1. Stop engine. 2. Check voltage between ECM terminals 67 and ground with CONSULT-II or tester.

SEF982W

Voltage: Battery voltage OK or NG OK

©

GO TO 11.

NG

©

GO TO 10.

10

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between ECM and fuse

©

11

Repair harness or connectors.

CHECK POWER SUPPLY-III

1. Turn ignition switch “ON” and then “OFF”. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.

SEF983W

Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK

©

GO TO 17.

NG (Battery voltage does not exist.)

©

GO TO 12.

NG (Battery voltage exists for more than a few seconds.)

©

GO TO 16.

EC-107

TROUBLE DIAGNOSIS FOR POWER SUPPLY

QG16I18DE

Main Power Supply and Ground Circuit (Cont’d)

12

CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM

1. Disconnect ECM harness connector. 2. Disconnect ECM relay.

SEF984W

3. Check harness continuity between ECM terminals 110, 112 and relay terminal 5. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 14.

NG

©

GO TO 13.

13

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and ECM

©

14

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK VOLTAGE BETWEEN ECM RELAY AND GROUND

Check voltage between relay terminals 1, 3 and ground with CONSULT-II or tester.

SEF985W

Voltage: Battery voltage OK or NG OK

©

GO TO 16.

NG

©

GO TO 15.

15

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM relay and fuse.

©

Repair harness or connectors.

EC-108

TROUBLE DIAGNOSIS FOR POWER SUPPLY

QG16I18DE

Main Power Supply and Ground Circuit (Cont’d)

16

CHECK ECM RELAY

1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5, 6 and 7.

SEC202BC

12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK

©

GO TO 17.

NG

©

Replace ECM relay.

17

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 18.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

18

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-109

QG16I18DE

DTC P0100 MASS AIR FLOW SENSOR (MAFS) Component Description

Component Description

SEF987W

NCEC0050

The mass air flow sensor is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. It consists of a hot wire that is supplied with electric current from the ECM. The temperature of the hot wire is controlled by the ECM a certain amount. The heat generated by the hot wire is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0051

Specification data are reference values. MONITOR ITEM

MAS A/F SE-B1

CAL/LD VALUE

MASS AIRFLOW

CONDITION I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

SPECIFICATION

Idle

1.0 - 1.7V

2,500 rpm

1.5 - 2.1V

Idle

Not used

2,500 rpm

Not used

Idle

1.0 - 4.0 g⋅m/s

2,500 rpm

5.0 - 10.0 g⋅m/s

ECM Terminals and Reference Value

NCEC0052

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

61

73

WIRE COLOR

B

ITEM

Mass air flow sensor

Mass air flow sensor ground

W

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

1.0 - 1.7V

[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm

1.5 - 2.1V

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

On Board Diagnosis Logic DTC No. P0100* 0100

Malfunction is detected when ...

Check Items (Possible Cause)

A)

An excessively high voltage from the sensor is sent I Harness or connectors to ECM when engine is not running. (The sensor circuit is open or shorted.) I Mass air flow sensor

B)

An excessively low voltage from the sensor is sent to ECM when engine is running.

I Harness or connectors (The sensor circuit is open or shorted.) I Intake air leaks I Mass air flow sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.

EC-110

NCEC0053

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

QG16I18DE

DTC Confirmation Procedure Detected items

Engine operating condition in fail-safe mode

Mass air flow sensor circuit

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

DTC Confirmation Procedure

NCEC0054

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A

NCEC0054S01

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-113. With GST Follow the procedure “With CONSULT-II” above. NEF068A

PROCEDURE FOR MALFUNCTION B

NCEC0054S02

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 2 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-113. With GST Follow the procedure “With CONSULT-II” above. NEF068A

EC-111

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0056

YEC063A

EC-112

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0057

INSPECTION START

Which malfunction (A, or B) is duplicated? Malfunction A or B A

©

GO TO 3.

B

©

GO TO 2.

2

CHECK INTAKE SYSTEM

Check the following for connection. I Air duct I Vacuum hoses I Intake air passage between air duct to collector OK or NG OK

©

GO TO 3.

NG

©

Reconnect the parts.

3

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

GO TO 4.

EC-113

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK POWER SUPPLY

1. Disconnect mass air flow sensor harness connector.

SEF995W

2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 4 and ground with CONSULT-II or tester.

SEF996W

Voltage: Battery voltage OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and mass air flow sensor I Harness for open or short between mass air flow sensor and ECM

©

6

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor harness connector terminal 3 and ECM terminal 73. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 7.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-114

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

QG16I18DE

Diagnostic Procedure (Cont’d)

7

CHECK INPUT SIGNAL CIRCUIT

1. Check harness continuity between mass air flow sensor harness connector terminal 5 and ECM terminal 61. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

8

CHECK MASS AIR FLOW SENSOR

Refer to “Component Inspection”, EC-QG-115. OK or NG OK

©

GO TO 9.

NG

©

Replace mass air flow sensor.

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0058

MASS AIR FLOW SENSOR 1. 2. 3.

Conditions Ignition switch “ON” (Engine stopped.) SEF993W

NCEC0058S01

Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 61 (Mass air flow sensor signal) and ground. Voltage V Less than 1.2

Idle (Engine is warmed-up to normal operating temperature.)

1.0 - 1.7

2,500 rpm (Engine is warmed-up to normal operating temperature.)

1.7 - 2.1

Idle to about 4,000 rpm*

1.0 - 1.7 to Approx. 4.0

*: Check for linear voltage rise in response to increases to about 4,000 rpm in engine speed.

4.

SEF987W

5.

If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.

EC-115

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

QG16I18DE

Component Description

Component Description

NCEC0066

The intake air temperature sensor is built into the mass air flow sensor. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise.

SEF987W

Intake air temperature °C (°F)

Voltage* V

Resistance kΩ

20 (68)

3.5

2.2 - 2.6

80 (176)

1.23

0.31 - 0.37

*: These data are reference values and are measured between ECM terminal 64 (Intake air temperature sensor) and ground. SEF012P

CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

On Board Diagnosis Logic DTC No. P0110 0110

Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM.

NCEC0067

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Intake air temperature sensor

DTC Confirmation Procedure

NCEC0068

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-118. With GST Follow the procedure “With CONSULT-II” above. NEF068A

EC-116

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

QG16I18DE Wiring Diagram

Wiring Diagram

INTAKE AIR TEMPERATURE SENSOR

NCEC0069

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC772

EC-117

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect intake air temperature sensor (mass air flow sensor) harness connector.

SEF995W

3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

NEF228A

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and intake air temperature sensor

©

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between intake air temperature sensor (mass air flow sensor) harness connector terminal 3 and ECM terminal 73. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-118

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

QG16I18DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and intake air temperature sensor

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-QG-119. OK or NG OK

©

GO TO 6.

NG

©

Replace intake air temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0071

INTAKE AIR TEMPERATURE SENSOR

NCEC0071S01

Check resistance between mass air flow sensor terminal 1 and 3.

Intake air temperature °C (°F)

Resistance kΩ

20 (68)

2.1 - 2.9

80 (176)

0.27 - 0.38

If NG, replace mass air flow sensor. SEF012P

EC-119

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Component Description

Component Description

NCEC0072

The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

SEF594K

Engine coolant temperature °C (°F)

Voltage* V

Resistance kΩ

−10 (14)

4.4

7.0 - 11.4

20 (68)

3.5

2.1 - 2.9

50 (122)

2.2

0.68 - 1.00

90 (194)

0.9

0.236 - 0.260

SEF012P

*: These data are reference values and are measured between ECM terminal 70 (Engine coolant temperature sensor) and ground.

CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0073

MONITOR ITEM COOLAN TEMP/S

CONDITION

SPECIFICATION

I Engine: After warming up

More than 70°C (158°F)

On Board Diagnosis Logic DTC No. P0115 0115

Malfunction is detected when ... I An excessively high or low voltage from the sensor is sent to ECM.*

NCEC0074

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Engine coolant temperature sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items

Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. Engine coolant temperature decided (CONSULT-II display)

Condition Engine coolant temperature sensor circuit

Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or Start

80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while the engine is running.

EC-120

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) DTC Confirmation Procedure

DTC Confirmation Procedure

NEF068A

NCEC0075

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-123. With GST Follow the procedure “With CONSULT-II” above.

EC-121

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Wiring Diagram

Wiring Diagram

NCEC0076

YEC261

EC-122

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Diagnostic Procedure

Diagnostic Procedure 1

NCEC0077

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect engine coolant temperature sensor harness connector.

SEF999W

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF997W

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor.

©

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between engine coolant temperature sensor harness connector terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and engine coolant temperature sensor

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-123

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR QG16I18DE (ECTS) (CIRCUIT) Diagnostic Procedure (Cont’d)

5

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-QG-124. OK or NG OK

©

GO TO 6.

NG

©

Replace engine coolant temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0078

ENGINE COOLANT TEMPERATURE SENSOR Check resistance as shown in the figure.

SEF152P

Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

EC-124

NCEC0078S01

QG16I18DE

DTC P0120 THROTTLE POSITION SENSOR

Component Description

Component Description

NCEC0079

Throttle position sensor

Output voltage between terminal No. 2 and 3 (V)

The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the ECM. Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sensor. This sensor controls engine operation such as fuel cut. On the other hand, the “Wide open and closed throttle position switch”, which is built into the throttle position sensor unit, is not used for engine control.

Supply voltage: 5V (Applied between terminal No. 1 and 3)

Output voltage between terminal No. 2 and 3)

Throttle valve opening angle (deg) NEF245A

CONSULT-II Reference Value in Data Monitor Mode

NCEC0080

Specification data are reference values. MONITOR ITEM

THRTL POS SEN

ABSOL TH⋅P/S

CONDITION

SPECIFICATION

I Engine: Idle

Throttle valve fully closed

0.35 - 0.65V

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

3.7 - 4.5V

I Engine: Idle

Throttle valve fully closed

0.0°

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

Approx. 80°

EC-125

QG16I18DE

DTC P0120 THROTTLE POSITION SENSOR ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NCEC0081

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 58

92

111

WIRE COLOR

B

Y

G

ITEM

CONDITION

Sensors’ ground

Throttle position sensor

Sensors’ power supply

DATA (DC Voltage)

[Engine is running] I Warm up condition I Idle speed

Approximately 0V

[Engine is running] I Accelerator pedal fully released

0.35 - 0.65V

[Ignition switch “ON”] I Accelerator pedal fully depressed

3.7 - 4.5V

[Ignition switch “ON”]

Approximately 5V

On Board Diagnosis Logic DTC No. P0120* 0120

Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM while driving.

NCEC0082

Check Items (Possible Cause) I Harness or connectors (The throttle position sensor circuit is open or shorted.) I Throttle position sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items

Engine operating condition in fail-safe mode Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor.

Throttle position sensor circuit

Condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure

NCEC0083

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 10V at idle. I This test may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-126

DTC P0120 THROTTLE POSITION SENSOR

QG16I18DE

DTC Confirmation Procedure (Cont’d)

With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and maintain the following conditions for at least 5 consecutive seconds.

PEF651U

VHCL SPEED SE

More than 4 km/h (2 MPH)

Selector lever

Suitable position except “N” position

3)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-129. With GST Follow the procedure “With CONSULT-II” above.

EC-127

DTC P0120 THROTTLE POSITION SENSOR

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0084

YEC064A

EC-128

DTC P0120 THROTTLE POSITION SENSOR

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0085

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

2

GO TO 2.

CHECK POWER SUPPLY

1. Disconnect throttle position sensor harness connector. Throttle position sensor harness connector

Throttle body

IACV-AAC valve harness connector NEF246A

2. Turn ignition switch “ON”. 3. Check voltage between terminal 3 and ground with CONSULT-II or tester.

SEF209W

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

Repair harness or connectors.

EC-129

DTC P0120 THROTTLE POSITION SENSOR

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between throttle position sensor harness connector terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and throttle position sensor.

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 92 and throttle position sensor harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK THROTTLE POSITION SENSOR

Refer to “Component Inspection”, EC-QG-131. OK or NG OK

©

GO TO 7.

NG

©

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-QG-72.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-130

DTC P0120 THROTTLE POSITION SENSOR

QG16I18DE Component Inspection

Component Inspection

NCEC0086

THROTTLE POSITION SENSOR

NEF069A

NCEC0086S01

With CONSULT-II 1) Stop engine (ignition switch OFF). 2) Turn ignition switch ON. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check voltage of “THRTL POS SEN” under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. Throttle valve conditions Completely closed Partially open Completely open

5)

Voltage (V) 0.35 - 0.65 (a) Between (a) and (b) 3.7 - 4.5 (b)

If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-QG-72. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.

Without CONSULT-II Stop engine (ignition switch OFF). Turn ignition switch ON. Check voltage between ECM terminal 92 (Throttle position sensor signal) and ground under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. 1) 2) 3)

Throttle valve conditions SEF007X

Completely closed Partially open Completely open

4)

Voltage (V) 0.35 - 0.65 (a) Between (a) and (b) 3.7 - 4.5 (b)

If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-QG-72. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.

EC-131

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE

Component Description

Component Description

NLEC0094

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NLEC0095

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NLEC0096

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL NO. COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-132

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0097

Under the condition in which the heated oxygen sensor 1 (front) signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long.

SEF237U

DTC No. P0130 0130

Malfunction is detected when ... I The voltage from the sensor is constantly approx. 0.3V.

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)

DTC Confirmation Procedure

SEF825Y

SEF826

NLEC0098

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1) P0130” of “HO2S1 (B1)” in “DTC WORK SUPPORT” mode with CONSULT-II. 3) Touch “START”. 4) Let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 4. 5) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.) ENG SPEED

1,700 - 3,200 rpm

Vehicle speed

Above 64 km/h (40 MPH)

B/FUEL SCHDL

Above 3.0 msec

Selector lever

Suitable position

SEF645Y

6)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG

EC-133

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE

Overall Function Check

RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-136.

Overall Function Check

SEF011X

NLEC0099

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-QG-136.

EC-134

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0100

YEC065A

EC-135

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NLEC0101

INSPECTION START

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

3. Disconnect heated oxygen sensor 1 (front) harness connector.

SEF012XA

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-137. OK or NG OK

©

GO TO 4.

NG

©

Replace heated oxygen sensor 1 (front).

4

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-136

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

SEF647Y

NLEC0102 NLEC0102S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF648Y

1) 2) 3) I

SEF011X

I I

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.

EC-137

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

QG16I18DE

Component Inspection (Cont’d)

I The voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

EC-138

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

Component Description

Component Description

NLEC0103

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NLEC0104

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NLEC0105

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-139

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0106

To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected.

SEF300U

DTC No. P0131 0131

Malfunction is detected when ... I The maximum and minimum voltages from the sensor are not reached to the specified voltages.

Check Items (Possible Cause) I I I I I

Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) Fuel pressure Injectors Intake air leaks

DTC Confirmation Procedure

SEF827Y

SEF828Y

NLEC0107

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0131” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.)

SEF651Y

EC-140

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

DTC Confirmation Procedure (Cont’d) ENG SPEED

1,700 - 2,600 rpm

Vehicle speed

64 - 100 km/h (40 - 62 MPH)

B/FUEL SCHDL

3.0 - 5.2 msec

Selector lever

Suitable position

7)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-141.

Overall Function Check

SEF011X

Diagnostic Procedure 1

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©

NLEC0108

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is over 0.6V at least one time. I The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-QG-141.

GO TO 2.

EC-141

NLEC0109

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

2

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

SEF995W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171. Refer to EC-QG-208.

No

©

GO TO 3.

3

CHECK FRONT HEATED OXYGEN SENSOR HEATER

Refer to “Component Inspection”, EC-QG-170. OK or NG OK

©

GO TO 4.

NG

©

Replace front heated oxygen sensor.

EC-142

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-143. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. Refer to “Wiring Diagram”, EC-QG-135, for circuit. ©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)

SEF646Y

SEF647Y

NLEC0110 NLEC0110S02

EC-143

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

QG16I18DE

Component Inspection (Cont’d)

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)

SEF011X

EC-144

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

Component Description

Component Description

NLEC0111

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NLEC0112

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NLEC0113

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-145

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0114

To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high. The “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected.

SEF299UA

DTC No. P0132 0132

Malfunction is detected when ... I The maximum and minimum voltages from the sensor are beyond the specified voltages.

Check Items (Possible Cause) I I I I

Heated oxygen sensor 1 (front) Heated oxygen sensor 1 heater (front) Fuel pressure Injectors

DTC Confirmation Procedure

SEF829Y

SEF830Y

NLEC0115

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0132” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED

1,700 - 2,600 rpm

Vehicle speed

64 - 100 km/h (40 - 62 MPH)

B/FUEL SCHDL

3.0 - 5.2 msec

Selector lever

Suitable position

SEF655Y

EC-146

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

DTC Confirmation Procedure (Cont’d)

7)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-147.

Overall Function Check

SEF011X

Diagnostic Procedure 1

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©

NLEC0116

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is below 0.8V at least one time. I The minimum voltage is below 0.3V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-QG-147.

GO TO 2.

EC-147

NLEC0117

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

2

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

SEF995W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.

No

©

GO TO 3.

3

CHECK HARNESS CONNECTOR

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector. 3. Check harness connector for water. Water should not exit. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace harness connector.

EC-148

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)

Refer to “Component Inspection”, EC-QG-170. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-149. OK or NG OK

©

GO TO 6.

NG

©

Replace heated oxygen sensor 1 (front).

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. Refer to “Wiring Diagram”, EC-QG-135, for circuit. ©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)

SEF646Y

SEF647Y

NLEC0118 NLEC0118S02

EC-149

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

QG16I18DE

Component Inspection (Cont’d)

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator lamp goes on more than 5 times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1) 2)

SEF011X

EC-150

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Component Description

Component Description

NLEC0119

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NLEC0120

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NLEC0121

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-151

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0122

To judge the malfunction of heated oxygen sensor 1 (front), this diagnosis measures response time of heated oxygen sensor 1 (front) signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 (front) temperature index. Judgment is based on whether the compensated time [heated oxygen sensor 1 (front) cycling time index] is inordinately long or not. SEF010V

DTC No. P0133 0133

Malfunction is detected when ...

Check Items (Possible Cause)

I The response of the voltage signal from the sensor takes I Harness or connectors more than the specified time. (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front) I Heated oxygen sensor 1 heater (front) I Fuel pressure I Injectors I Intake air leaks I Exhaust gas leaks I PCV I Mass air flow sensor

DTC Confirmation Procedure

SEF831Y

SEF832Y

NLEC0123

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds.) ENG SPEED

2,100 - 3,100 rpm

Vehicle speed

80 - 120 km/h (50 - 75 MPH)

B/FUEL SCHDL

3.8 - 7.6 msec

Selector lever

Suitable position

SEF658Y

EC-152

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Overall Function Check

7)

Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-155.

Overall Function Check

SAT652J

NLEC0124

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set ECM in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT)]. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] 4) If NG, go to “Diagnostic Procedure”, EC-QG-155.

EC-153

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0125

YEC065A

EC-154

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NLEC0126

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©

3

GO TO 3.

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

SEF099P

OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 5.

NG

©

Repair or replace.

EC-155

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

5

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

JEF105Y

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 or 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171, P0172. Refer to EC-QG-208, 215.

No

©

GO TO 6.

6

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 7.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-156

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)

Refer to “Component Inspection”, EC-QG-170. OK or NG OK

©

GO TO 8.

NG

©

Replace heated oxygen sensor 1 (front).

8

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-158. OK or NG OK

©

GO TO 9.

NG

©

Replace heated oxygen sensor 1 (front).

9

CHECK MASS AIR FLOW SENSOR

Refer to “Component Inspection”, EC-QG-115. OK or NG OK

©

GO TO 10.

NG

©

Replace mass air flow sensor.

10

CHECK PCV VALVE

Refer to “Positive Crankcase Ventilation”, EC-QG-28. OK or NG OK

©

GO TO 11.

NG

©

Repair or replace PCV valve.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-157

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

SEF647Y

NLEC0127 NLEC0127S02

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF648Y

1) 2) 3) I

SEF011X

I I

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.

EC-158

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

QG16I18DE

Component Inspection (Cont’d)

I The voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

EC-159

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE

Component Description

Component Description

NLEC0128

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NLEC0129

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NLEC0130

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-160

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0131

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 (front) output is not inordinately high.

SEF301U

DTC No. P0134 0134

Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)

DTC Confirmation Procedure

SEF174Y

NLEC0132

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON”. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 2 minutes. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-163. With GST 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Restart engine and let it idle for 2 minutes. 4) Turn ignition switch “OFF” and wait at least 9 seconds. 5) Restart engine and let it idle for 2 minutes. 6) Select “MODE 3” with GST. 7) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-163. I When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.

EC-161

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0133

YEC065A

EC-162

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NLEC0134

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) ©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.

SEF012XA

2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 1 (front) harness connector for water. Water should not exist. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace harness connector.

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-164. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-163

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE

Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

SEF647Y

NLEC0135 NLEC0135S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF648Y

1) 2) 3) I

SEF011X

I I

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (HO2S1 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. Malfunction indicator lamp goes on more than five times within 10 seconds in Diagnostic Test Mode II [HEATED OXYGEN SENSOR 1 MONITOR (FRONT).] The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time.

EC-164

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

QG16I18DE

Component Inspection (Cont’d)

I The voltage never exceeds 1.0V. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

EC-165

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER

QG16I18DE

Description

Description

NLEC0136

SYSTEM DESCRIPTION

NLEC0136S01

Sensor

Input Signal to ECM

Camshaft position sensor (PHASE) Crankshaft position sensor (POS)

Engine speed

ECM function

Actuator

Heated oxygen sensor 1 heater (front) control

Heated oxygen sensor 1 heater (front)

The ECM performs ON/OFF control of the heated oxygen sensor 1 heater (front) corresponding to the engine operating condition.

OPERATION

NLEC0136S02

Engine speed

Heated oxygen sensor 1 heater (front)

Above 3,200 rpm

OFF

Below 3,200 rpm

ON

CONSULT-II Reference Value in Data Monitor Mode

NLEC0137

Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1)

CONDITION

SPECIFICATION

I Engine speed: Below 3,200 rpm

ON

I Engine speed: Above 3,200 rpm

OFF

ECM Terminals and Reference Value

NLEC0138

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

4

WIRE COLOR

L

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] Heated oxygen sensor 1 I Engine speed is below 3,200 rpm. heater (front) [Engine is running] I Engine speed is above 3,200 rpm.

Approximately 0V BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P0135 0135

Malfunction is detected when ... I The current amperage in the heated oxygen sensor 1 heater (front) circuit is out of the normal range. [An improper voltage drop signal is sent to ECM through the heated oxygen sensor 1 heater (front).]

EC-166

NLEC0139

Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 1 heater (front) circuit is open or shorted.) I Heated oxygen sensor 1 heater (front)

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NLEC0140

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at idle.

1) 2) 3)

SEF058Y

1) 2) 3) 4) 5) I

With CONSULT-II Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-169. With GST Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine and run it for at least 5 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-169. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.

EC-167

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0141

YEC066A

EC-168

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NLEC0142

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector.

SEF012XA

3. Turn ignition switch “ON”. 4. Check voltage between terminal 3 and ground with CONSULT-II or tester.

SEF025X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 I 10A fuse I Harness for open or short between heated oxygen sensor 1 (front) and fuse ©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 1 (front) harness connector terminal 1 and ECM terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-169

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK HEATED OXYGEN SENSOR 1 HEATER (FRONT)

Refer to “Component Inspection”, EC-QG-170. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 HEATER (FRONT)

SEF935X

NLEC0143 NLEC0143S01

Check resistance between terminals 3 and 1. Resistance: 2.3 - 4.3 Ω at 25°C (77°F) Check continuity between terminals 2 and 1, 3 and 2. Continuity should not exist. If NG, replace the heated oxygen sensor 1 (front). CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

EC-170

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE Component Description

Component Description

SEF327R

NLEC0144

The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NLEC0145

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NLEC0146

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63

WIRE COLOR

L

ITEM

Heated oxygen sensor 2 (rear)

CONDITION

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 3,000 rpm

On Board Diagnosis Logic

NLEC0147

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the minimum voltage of the sensor is sufficiently low during various driving conditions such as fuel-cut. SEF258VA

DTC No. P0137 0137

Malfunction is detected when ... I The minimum voltage from the sensor does not reach the specified voltage.

EC-171

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF682X

SEF684X

NLEC0594

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0137” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,500 - 3,600 rpm

Vehicle speed

Above 70 km/h (43 MPH)

B/FUEL SCHDL

Above 2.7 msec

Selector lever

4th gear position

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG175.

EC-172

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE Overall Function Check

Overall Function Check

SEF032X

NLEC0595

Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving engine up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 0.56V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.56V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-175.

EC-173

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

Wiring Diagram

Wiring Diagram

EC-174

NCEC0150

YEC067A

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0151

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

GO TO 2.

EC-175

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

2

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

SEF995W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.

No

©

GO TO 3.

EC-176

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.

SEF033X

3. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and body ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-QG-178. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-177

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

Component Inspection

Component Inspection HEATED OXYGEN SENSOR 2 (REAR)

SEF662Y

NLEC0152 NLEC0152S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF244YA

Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.56V at least once. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1)

SEF032X

EC-178

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

QG16I18DE

Component Inspection (Cont’d)

I

Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

EC-179

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Component Description

Component Description

SEF327R

NLEC0153

The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NLEC0154

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NLEC0155

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63

WIRE COLOR

L

ITEM

Heated oxygen sensor 2 (rear)

CONDITION

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 2,000 rpm

On Board Diagnosis Logic

NLEC0156

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the maximum voltage of the sensor is sufficiently high during various driving conditions such as fuel-cut. SEF259VA

DTC No. P0138 0138

Malfunction is detected when ... I The maximum voltage from the sensor does not reach the specified voltage.

EC-180

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF685X

SEF687X

NLEC0596

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0138” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,500 - 3,600 rpm

Vehicle speed

Above 70 km/h (43 MPH)

B/FUEL SCHDL

Above 2.7 msec

Selector lever

4th gear position

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG184.

EC-181

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Overall Function Check

Overall Function Check

SEF032X

NLEC0597

Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving engine up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be above 0.68V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-184.

EC-182

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE Wiring Diagram

Wiring Diagram

EC-183

NCEC0159

YEC067A

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NLEC0160

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

GO TO 2.

EC-184

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

2

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

SEF995W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171. Refer to EC-QG-208.

No

©

GO TO 3.

EC-185

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and heated oxygen sensor 2 (rear). ©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-QG-186. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 2 (REAR) 1) 2) 3) 4) SEF662Y

NLEC0161 NLEC0161S01

With CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes.. Stop vehicle with engine running. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%.

EC-186

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

QG16I18DE

Component Inspection (Cont’d)

CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF244YA

Without CONSULT-II Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.56V at least once. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)

SEF032X

EC-187

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

Component Description

Component Description

SEF327R

NLEC0162

The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NLEC0163

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NLEC0164

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63

WIRE COLOR

L

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm

On Board Diagnosis Logic

NLEC0165

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the switching response of the sensor’s voltage is faster than specified during various driving conditions such as fuel-cut. SEF302U

DTC No. P0139 0139

Malfunction is detected when ... I It takes more than the specified time for the sensor to respond between rich and lean.

EC-188

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF688X

SEF690X

NLEC0598

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,500 - 3,600 rpm

Vehicle speed

Above 70 km/h (43 MPH)

B/FUEL SCHDL

Above 2.7 msec

COOLAN TEMP/S

70 - 105°C (158 - 221°F)

Selector lever

4th gear position

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG192.

EC-189

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

Overall Function Check

Overall Function Check

SEF032X

NLEC0599

Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should change at more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-QG-192.

EC-190

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE Wiring Diagram

Wiring Diagram

EC-191

NCEC0168

YEC067A

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0169

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

GO TO 2.

EC-192

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

2

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “START”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed.

SEF995W

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “How to Erase Emission-related Diagnostic Information”, EC-QG-44. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-QG-215.

No

©

GO TO 3.

EC-193

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.

SEF033X

2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-QG-195. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-194

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

QG16I18DE Component Inspection

Component Inspection HEATED OXYGEN SENSOR 2 (REAR)

SEF662Y

NLEC0170 NLEC0170S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant.

SEF244YA

Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.56V at least once. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool 1)

SEF032X

EC-195

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING) Component Inspection (Cont’d)

and approved anti-seize lubricant.

EC-196

QG16I18DE

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE Component Description

Component Description

SEF327R

NLEC0171

The heated oxygen sensor 2 (rear), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NLEC0172

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NLEC0173

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63

WIRE COLOR

L

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm

On Board Diagnosis Logic

NLEC0174

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether or not the voltage is too high during various driving conditions such as fuelcut. SEF305U

DTC No. P0140 0140

Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.

EC-197

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear)

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF189Y

ENG SPEED

Above 1,500 rpm

VHCL SPEED SE

Above 70 km/h (43 MPH)

B/FUEL SCHDL

Above 2.7 msec

COOLAN TEMP/S

70 - 105°C (158 - 221°F)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-200.

Overall Function Check

SEF032X

NLEC0175

NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Stop vehicle with engine running. 4) Let engine idle for 1 minute. 5) Maintain the following conditions for at least 5 consecutive minutes.

NLEC0176

Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage after revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 2V during this procedure. 5) If NG, go to “Diagnostic Procedure”, EC-QG-200.

EC-198

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE Wiring Diagram

Wiring Diagram

EC-199

NCEC0177

YEC067A

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0178

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector.

SEF033X

2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 [or heated oxygen sensor 2 (rear) harness connector terminal 2] and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-200

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to power in harness or connectors.

5

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 2 (rear) harness connector for water. Water should not exist. OK or NG OK

©

GO TO 6.

NG

©

Repair or replace harness connector.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-QG-201. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 2 (REAR)

With CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.56V at least once when the “FUEL INJECTION” is −25%. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)

SEF662Y

NLEC0179 NLEC0179S01

EC-201

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

QG16I18DE

Component Inspection (Cont’d)

SEF244YA

Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (HO2S2 signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once. If the voltage is above 0.68V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.56V at least once. CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. 1)

SEF032X

EC-202

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)

QG16I18DE Description

Description

NLEC0180

SYSTEM DESCRIPTION

NLEC0180S01

Sensor

Input Signal to ECM

Camshaft position sensor (PHASE) Crankshaft position sensor (POS)

ECM function Heated oxygen sensor 2 heater (rear) control

Engine speed

Actuator

Heated oxygen sensor 2 heater (rear)

The ECM performs ON/OFF control of the heated oxygen sensor 2 heater (rear) corresponding to the engine speed.

OPERATION

NLEC0180S02

Engine condition

Heated oxygen sensor 2 heater (rear)

Engine stopped

OFF

Engine is running.

After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more

ON

Engine speed above 3,600 rpm

OFF

CONSULT-II Reference Value in Data Monitor Mode

NLEC0181

Specification data are reference values. MONITOR ITEM

HO2S2 HTR (B1)

CONDITION

I Engine speed

SPECIFICATION

Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

Above 3,600 rpm

OFF

I Ignition switch ON (Engine stopped)

OFF

ECM Terminals and Reference Value

NLEC0182

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL NO. COLOR

3

W/R

ITEM

Heated oxygen sensor 2 heater (rear)

CONDITION

DATA (DC Voltage)

[Engine is running] I Engine speed is below 3,600 rpm [After driving Approximately 0.7V for 2 minutes at a speed of 70 km/h (43 MPH) or more] [Engine is running] I Engine speed is above 3,600 rpm [Ignition switch “ON”] I Engine stopped

EC-203

BATTERY VOLTAGE (11 - 14V)

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P0141 0141

Malfunction is detected when ... I The current amperage in the heated oxygen sensor 2 heater (rear) circuit is out of the normal range. [An improper voltage drop signal is sent to ECM through the heated oxygen sensor 2 heater (rear).]

Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 2 heater (rear) circuit is open or shorted.) I Heated oxygen sensor 2 heater (rear)

DTC Confirmation Procedure

SEF175Y

NLEC0183

NLEC0184

NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is in between 10.5V and 16V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. Engine speed must be maintained at speeds of 3,600 rpm or less during vehicle operations. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-206. With GST 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. Engine speed must be maintained at speeds of 3,600 rpm or less during vehicle operations. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Select “MODE 3” with GST. 5) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-206. When using GST, “DTC Confirmation Procedure ” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended.

EC-204

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)

QG16I18DE Wiring Diagram

Wiring Diagram

EC-205

NCEC0185

YEC068A

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0186

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector.

SEF033X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 4 and ground.

SEF047X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 I Harness for open or short between heated oxygen sensor 2 (rear) and fuse I 10A fuse ©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 and ECM terminal 3. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-206

DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)

QG16I18DE

Diagnostic Procedure (Cont’d)

5

CHECK HEATED OXYGEN SENSOR 2 HEATER (REAR)

Refer to “Component Inspection”, EC-QG-207. OK or NG OK

©

GO TO 6.

NG

©

Replace heated oxygen sensor 2 (rear).

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

Component Inspection

NLEC0187

HEATED OXYGEN SENSOR 2 HEATER (REAR)

NLEC0187S01

Check the following. 1. Check resistance between terminals 1 and 4. Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity. Terminal No.

Continuity

2 and 1, 3, 4 No 3 and 1, 2, 4

If NG, replace the heated oxygen sensor 2 (rear). CAUTION: I Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. I Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. SEF048X

EC-207

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0188

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the Heated oxygen sensor 1 (front). The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor

Heated oxygen sensor 1 (front)

DTC No. P0171 0171

ECM function

Input Signal to ECM

Fuel injection & mixture ratio control

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)

Actuator

Injectors

Check Items (Possible Cause) I I I I I I I

Intake air leaks Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor

DTC Confirmation Procedure

NCEC0189

NEF068A

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG211. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-211. If engine does not start, visually check for exhaust and intake air leak.

SEF995W

With GST Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Select “MODE 7” with GST. Make sure 1st trip DTC P0100 is detected. Select “MODE 4” with GST and erase the 1st trip DTC P0100.

SEF652Y

1) 2) 3) 4) 5) 6)

EC-208

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

DTC Confirmation Procedure (Cont’d)

7)

Start engine again and run it for at least 10 minutes at idle speed. 8) Select “MODE 7” with GST. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG-211. 9) If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-211. If engine does not start, visually check for exhaust and intake air leak.

EC-209

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

Wiring Diagram

Wiring Diagram

EC-210

NCEC0190

YEC069A

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0191

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

SEF099P

OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

2

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

3

CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect Heated oxygen sensor 1 (front) harness connector and ECM harness connector.

SEF012XA

3. Check harness continuity between ECM terminal 62 and Heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-211

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-QG-29. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit Refer to EC-QG-336. I Fuel pressure regulator Refer to EC-QG-30. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging

©

6

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 5.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK

©

GO TO 7.

NG

©

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-110.

EC-212

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

7

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard. OK or NG OK

©

GO TO 8.

NG

©

Perform trouble diagnosis for “INJECTORS”, EC-QG-319.

8

REMOVE INJECTOR

1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector with fuel tube assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors should remain connected.

©

GO TO 9.

EC-213

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

9

CHECK INJECTOR

1. Disconnect all ignition coil harness connectors. 2. Place pans or saucers under each injector. 3. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.

SEF595Q

Fuel should be sprayed evenly for each cylinder. OK or NG OK

©

GO TO 10.

NG

©

Replace injectors from which fuel does not spray out. Always replace O-ring with new one.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-214

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0192

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the Heated oxygen sensor 1 (front). The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor

Heated oxygen sensor 1 (front)

DTC No. P0172 0172

ECM function

Input Signal to ECM

Fuel injection & mixture ratio control

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)

Actuator

Injectors

Check Items (Possible Cause) I I I I I

Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor

DTC Confirmation Procedure

NCEC0193

NEF068A

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG218. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-218. If engine does not start, remove ignition plugs and check for fouling, etc.

SEF995W

With GST Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 3 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Select “MODE 7” with GST. Make sure 1st trip DTC P0100 is detected. Select “MODE 4” with GST and erase the 1st trip DTC P0100.

SEF652Y

1) 2) 3) 4) 5) 6)

EC-215

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

DTC Confirmation Procedure (Cont’d)

7)

Start engine again and run it for at least 10 minutes at idle speed. 8) Select “MODE 7” with GST. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-QG-218. 9) If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-QG-218. If engine does not start, remove ignition plugs and check for fouling, etc.

EC-216

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE Wiring Diagram

Wiring Diagram

EC-217

NCEC0194

YEC069A

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0195

CHECK FOR EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.

SEF099P

OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

2

CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect Heated oxygen sensor 1 (front) harness connector and ECM harness connector.

SEF012XA

3. Check harness continuity between ECM terminal 62 and Heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-218

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-QG-29. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit (Refer to EC-QG-336.) I Fuel pressure regulator (Refer to EC-QG-30.)

©

5

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK

©

GO TO 6.

NG

©

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-113.

EC-219

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

6

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard. OK or NG OK

©

GO TO 7.

NG

©

Perform trouble diagnosis for “INJECTORS”, EC-QG-319319.

7

REMOVE INJECTOR

1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery.

©

8 1. 2. 3. 4.

GO TO 8.

CHECK INJECTOR Disconnect all injector harness connectors. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injectors. Crank engine for about 3 seconds. Make sure fuel does not drip from injector. OK or NG

OK (Does not drip)

©

GO TO 9.

NG (Drips)

©

Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

EC-220

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

QG16I18DE

Diagnostic Procedure (Cont’d)

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-221

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0202

When a misfire occurs, the engine speed will fluctuate. If the engine speed fluctuates enough to cause the CKP sensor signal to vary, The ECM can determine that a misfire is occurring. Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

ECM function

Engine speed

On board diagnosis of misfire

The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink. When a misfire condition occurs, the ECM monitors the CKP sensor signal every 200 engine revolutions for a change. When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink. When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on. If another misfire condition occurs that can damage the TWC, the MI will begin to blink again. (After the first trip detection, the MI will light up from engine starting. If a misfire is detected that will cause three way catalyst damage, the MI will start blinking.) 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect emissions), the MI will only light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor signal every 1,000 engine revolutions. A misfire malfunction can be detected on any one cylinder or on multiple cylinders. DTC No.

Malfunction is detected when ...

P0300 0300

I Multiple cylinders misfire.

P0301 0301

I No. 1 cylinder misfires.

P0302 0302

I No. 2 cylinder misfires.

P0303 0303

I No. 3 cylinder misfires.

P0304 0304

I No. 4 cylinder misfires.

Check Items (Possible Cause) I I I I I I I I I I

Improper spark plug Insufficient compression Incorrect fuel pressure EGR volume control valve (If so equipped) The injector circuit is open or shorted Injectors Intake air leak Insufficient ignition spark Lack of fuel Heated oxygen sensor 1 (front)

DTC Confirmation Procedure

NEF068A

NCEC0203

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”, and select “DATA MONITOR” mode with CONSULT-II.

EC-222

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

DTC Confirmation Procedure (Cont’d)

2) 3) 4)

Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes. Hold the accelerator pedal as steady as possible. NOTE: Refer to the freeze frame data for the test driving conditions. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-223. With GST Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure 1

CHECK FOR INTAKE AIR LEAK

1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. OK or NG OK

©

GO TO 2.

NG

©

Discover air leak location and repair.

2

CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace it.

3

CHECK EGR FUNCTION (If so equipped)

Perform DTC Confirmation Procedure for DTC P1402 EGR FUNCTION (OPEN). Refer to EC-QG-305. OK or NG OK

©

GO TO 4.

NG

©

Repair EGR system.

EC-223

NCEC0204

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

Diagnostic Procedure (Cont’d)

4

PERFORM POWER BALANCE TEST

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

NEF105A

2. Is there any cylinder which does not produce a momentary engine speed drop? Without CONSULT-II When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop?

SEF055X

Yes or No Yes

©

GO TO 5.

No

©

GO TO 7.

5

CHECK INJECTOR

Does each injector make an operating sound at idle?

MEC703B

Yes or No Yes

©

GO TO 6.

No

©

Check injector(s) and circuit(s). Refer to EC-QG-319.

EC-224

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4. 5.

CHECK IGNITION SPARK Turn Ignition switch “OFF”. Disconnect ignition coil assembly from rocker cover. Connect a known good spark plug to the ignition coil assembly. Place end of spark plug against a suitable ground and crank engine. Check for spark.

SEF575Q

OK or NG OK

©

GO TO 7.

NG

©

Check ignition coil, power transistor and their circuits. Refer to EC-QG-323.

7

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

SEF156I

OK or NG OK

©

GO TO 8.

NG

©

Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE” in MA section.

8

CHECK COMPRESSION PRESSURE

Refer to EM section. I Check compression pressure. Standard: 1,324 kPa (13.24 bar, 13.5 kg/cm2, 192 psi)/350 rpm Minimum: 1,128 kPa (11.28 bar, 11.5 kg/cm2, 164 psi)/350 rpm Difference between each cylinder: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)/350 rpm OK or NG OK

©

GO TO 9.

NG

©

Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

EC-225

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

Diagnostic Procedure (Cont’d)

9

CHECK FUEL PRESSURE

1. Install any parts removed. 2. Release fuel pressure to zero. Refer to EC-QG-29. 3. Install fuel pressure gauge and check fuel pressure.

SEF925W

At idle: Approx. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) OK or NG OK

©

GO TO 11.

NG

©

GO TO 10.

10

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit Refer to EC-QG-336. I Fuel pressure regulator Refer to EC-QG-30. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging ©

11

Repair or replace.

CHECK IGNITION TIMING

Perform “Basic Inspection”. Refer to EC-QG-72. OK or NG OK

©

GO TO 12.

NG

©

1. Perform “Idle Air Volume Learning”. Refer to EC-QG-33. 2. Check camshaft position sensor (PHASE) (EC-QG-238) and crankshaft position sensor (POS) (EC-QG-232).

12

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-QG-231. OK or NG OK

©

GO TO 13.

NG

©

Replace Heated oxygen sensor 1 (front).

EC-226

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

QG16I18DE

Diagnostic Procedure (Cont’d)

13

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 1.0 - 4.0 g⋅m/sec at 2,500 rpm: 5.0 - 10.0 g⋅m/sec OK or NG OK

©

GO TO 15.

NG

©

GO TO 14.

14

CHECK CONNECTORS

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-QG-110. OK or NG NG

15

©

Repair or replace it.

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-QG-82. OK or NG OK

©

GO TO 16.

NG

©

Repair or replace.

16

ERASE THE 1ST TRIP DTC

Some tests may cause a 1st trip DTC to be set. Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-QG-44. ©

17

GO TO 17.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-227

QG16I18DE

DTC P0325 KNOCK SENSOR (KS) Component Description

Component Description

NCEC0206

The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. Freeze frame data will not be stored in the ECM for the knock sensor. The MI will not light for knock sensor malfunction. The knock sensor has one trip detection logic. SEF598K

ECM Terminals and Reference Value

NCEC0207

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 81

WIRE COLOR W

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Idle speed

Knock sensor

1.0 - 4.0V

On Board Diagnosis Logic DTC No. P0325 0325

Malfunction is detected when ... I An excessively low or high voltage from the knock sensor is sent to ECM.

Check Items (Possible Cause) I Harness or connectors (The knock sensor circuit is open or shorted.) I Knock sensor

DTC Confirmation Procedure

NEF068A

NCEC0208

NCEC0209

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 5 seconds at idle speed. 3) If DTC is detected, go to “Diagnostic Procedure”, EC-QG-230. With GST Follow the procedure “With CONSULT-II” above.

EC-228

DTC P0325 KNOCK SENSOR (KS)

QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0210

ECM

Detectable line for DTC Non-detectable line for DTC

KNOCK SENSOR

EC-229

YEC269

DTC P0325 KNOCK SENSOR (KS)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0211

RETIGHTEN GROUND SCREWS

Loosen and retighten engine ground screws.

SEF994W

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT-1

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and knock sensor harness connector. View from the underside of the vehicle Knock sensor harness connector

Oil filter

SEF056X

3. Check harness continuity between knock sensor signal terminal 2 and ECM terminal 81. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between knock sensor and ECM.

©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK KNOCK SENSOR

Knock sensor Refer to “Component Inspection”, EC-QG-231. OK or NG OK

©

GO TO 5.

NG

©

Replace knock sensor.

EC-230

DTC P0325 KNOCK SENSOR (KS)

QG16I18DE Diagnostic Procedure (Cont’d)

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection KNOCK SENSOR I 1. 2.

NCEC0212 NCEC0212S01

Use an ohmmeter which can measure more than 10 MΩ. Disconnect knock sensor harness connector. Check resistance between terminal 2 and ground. Resistance: 500 - 620 kΩ [at 25°C (77°F)] CAUTION: Discard any knock sensors that have been dropped or physically damaged. Use only new ones.

SEF057X

EC-231

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

Component Description

Component Description

SEF058X

SEF117X

NCEC0551

The crankshaft position sensor is located on the right rear wall of the cylinder block in relation to the signal plate on the No. 6 counterweight. The crankshaft position sensor is a basic component of the engine control system. It monitors engine speed, piston position, and fluctuation of the engine revolution. These input signals to the engine control system are used to control fuel injection, ignition timing and other functions. The sensor consists of a permanent magnet, core and coil. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The signal plate is provided with 34 teeth to emit a signal at an interval of 10° during crankshaft operations. However, it is not provided with 2 teeth to emit a signal at an interval of 180°. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives a voltage signal to provide “time processing” for engine speed, piston position and fluctuation of engine revolutions. This sensor is not used to control the engine system. It is used only for the on board diagnosis.

ECM Terminals and Reference Value

NCEC0552

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (AC Voltage) 3 - 4V

[Engine is running] I Warm-up condition I Idle speed

85

W

SEF979W

Crankshaft position sensor

3 - 4V

[Engine is running] I Engine speed is 2,000 rpm

SEF980W

EC-232

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic DTC No. P0335 0335

Malfunction is detected when ... I The 10° signal is not entered to ECM for the first few seconds during engine cranking. .......................................................................................................... I The 10° signal is not entered to ECM during engine running. .......................................................................................................... I The 10° signal is not in the normal pattern at each engine revolution.

Check Items (Possible Cause) I Harness or connectors (The crankshaft position sensor (POS) circuit is open or shorted.) I Crankshaft position sensor (POS) I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.) I Dead (Weak) battery

DTC Confirmation Procedure

NEF068A

NCEC0553

NCEC0554

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-235. With GST Follow the procedure “With CONSULT-II” above.

EC-233

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

Wiring Diagram

Wiring Diagram

EC-234

NCEC0555

YEC070A

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0556

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

2

GO TO 2.

CHECK POWER SUPPLY

1. Disconnect crankshaft position sensor harness connector.

SEF117X

2. Turn ignition switch “ON”. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.

YEC132A

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-235

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between crankshaft position sensor and ECM relay I Harness for open or short between crankshaft position sensor and ECM I ECM relay ©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect crankshaft position sensor and ECM harness connectors.

SEF117X

2. Check continuity between ECM terminal 85 and crankshaft position sensor harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK GROUND CIRCUIT

1. Reconnect ECM harness connector. 2. Check harness continuity between terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK CRANKSHAFT POSITION SENSOR

Refer to “Component Inspection”, EC-QG-237. OK or NG OK

©

GO TO 7.

NG

©

Replace crankshaft position sensor.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-236

DTC P0335 CRANKSHAFT POSITION SENSOR (POS)

QG16I18DE

Component Inspection

Component Inspection

NCEC0557

CRANKSHAFT POSITION SENSOR (POS) 1.

NCEC0557S01

2. 3. 4.

Disconnect crankshaft position sensor (POS) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.

5.

Check resistance as shown in the figure.

SEF121X

Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) - 1 (−) 2 (+) - 1 (−)

Except 0 or ∞

3 (+) - 2 (−)

If NG, replace crankshaft position sensor. SEF122X

EC-237

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE

Component Description

Component Description

SEF058X

NCEC0220

The camshaft position sensor senses the protrusion provided with exhaust valve cam sprocket to identify a particular cylinder. The crankshaft position sensor senses the piston position. When the crankshaft position sensor system becomes inoperative, the camshaft position sensor provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet, core and coil. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes.

ECM Terminals and Reference Value

NCEC0221

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 3 - 4V

[Engine is running] I Warm-up condition I Idle speed

SEF977W

66* 75

W

Camshaft position sensor (PHASE)

3 - 4V

[Engine is running] I Engine speed is 2,000 rpm

SEF978W

*: If so equipped

On Board Diagnosis Logic DTC No. P0340 0340

NCEC0222

Malfunction is detected when ...

Check Items (Possible Cause)

I The cylinder No. signal is not entered to ECM for the first few seconds during engine cranking. ................................................................................................. I The cylinder No. signal is not enter to ECM during engine running. ................................................................................................. I The cylinder No. signal is not in the normal pattern during engine running.

I Harness or connectors (The camshaft position sensor (PHASE) circuit is open or shorted.) I Camshaft position sensor (PHASE) I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.)

EC-238

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NCEC0223

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V.

With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-241. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)

PEF002P

EC-239

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE

Wiring Diagram

Wiring Diagram

EC-240

NCEC0224

YEC071A

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0225

CHECK STARTING SYSTEM

Does the engine turn over? (Does the starter motor operate?) Yes or No Yes

©

GO TO 2.

No

©

Check starting system. (Refer to EL section.)

2

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

SEF994W

©

3

GO TO 3.

CHECK POWER SUPPLY

1. Disconnect camshaft position sensor harness connector.

2. Turn ignition switch “ON”. 3. Check voltage between terminal 1 and ground with CONSULT-II or tester.

Voltage: Battery voltage

SEF060X

SEF061X

OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-241

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between camshaft position sensor and ECM relay I Harness for open or short between camshaft position sensor and ECM

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 2 and ECM terminal 75. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between sensor terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 7.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

7

CHECK CAMSHAFT POSITION SENSOR

Refer to “Component Inspection”, EC-QG-243. OK or NG OK

©

GO TO 8.

NG

©

Replace camshaft position sensor.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-242

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)

QG16I18DE

Component Inspection

Component Inspection

=NCEC0226

CAMSHAFT POSITION SENSOR 1. 2. 3. 4. 5. SEF122X

NCEC0226S01

Disconnect camshaft position sensor (PHASE) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping. Check resistance as shown in the figure. Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) - 1 (−) 2 (+) - 1 (−) 3 (+) - 2 (−)

If NG, replace camshaft position sensor.

EC-243

Except 0 or ∞

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Description

Description

NCEC0227

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

ECM function

EGR control

NCEC0227S01

Actuator

EGR volume control valve

Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Battery

Battery voltage

This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains closed under the following conditions. I Low engine coolant temperature I Engine starting I High-speed engine operation I Extremely light load engine operation I Engine idling I Excessively high engine coolant temperature I Wide open throttle I Mass air flow sensor malfunction I Low battery voltage

SEF551W

COMPONENT DESCRIPTION EGR Volume Control Valve

NCEC0227S02 NCEC0227S0201

The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W

EC-244

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0502

Specification data are reference values. MONITOR ITEM

CONDITION

EGR TEMP SEN

I Engine: After warming up

EGR VOL CON/V

I I I I

SPECIFICATION Less than 4.5V

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

0 step

Revving engine up to 3,000 rpm quickly

10 - 55 step

ECM Terminals and Reference Value

NCEC0503

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage)

8 9 17 18

W/B SB G/R R/Y

EGR volume control valve

[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm

0 - 14V

58

B

Sensor’s ground

[Engine is running] I Warm-up condition I Idle speed

0V

[Engine is running] I Warm-up condition I Idle speed

Less than 4.5V

[Engine is running] I Warm-up condition I EGR system is operating.

0 - 1V

72

PU

EGR temperature sensor

On Board Diagnosis Logic

NCEC0228

If the absence of EGR flow is detected by EGR temperature sensor under the condition that calls for EGR, a low-flow malfunction is diagnosed.

SEF073P

DTC No. P0400 0400

Malfunction is detected when ... I No EGR flow is detected under conditions that call for EGR.

EC-245

Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EGR valve stuck closed I Dead (Weak) battery I EGR passage I EGR temperature sensor I Exhaust gas leaks

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure

DTC Confirmation Procedure

NEF107A

NEF108A

PEF785UA

NCEC0229

CAUTION: Always drive vehicle at a safe speed. NOTE: I If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. I P0400 will not be displayed at “SELF-DIAG RESULTS” mode with CONSULT-II even though DTC work support test result is “NG”. TESTING CONDITION: I Before performing the following procedure, confirm battery voltage is more than 10V at idle, then stop engine immediately. I It will be better to perform the test at a temperature above 0°C (32°F). With CONSULT-II 1) Turn ignition switch “ON”. 2) Check “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II and confirm it is within the range listed below. COOLAN TEMP/S: Less than 40°C (104°F) If the value is out of range, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to lower the coolant temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. 3) Start engine and let it idle monitoring “COOLAN TEMP/S” value. When the “COOLAN TEMP/S” value reaches 70°C (158°F), immediately go to the next step. 4) Select “EGR SYSTEM P0400” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. 5) Touch “START”. 6) Accelerate vehicle to a speed of 40 km/h (25 MPH) once and then stop vehicle with engine running. If “COMPLETED” appears on CONSULT-II screen, go to step 8. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions until “TESTING” changes to “COMPLETED”. (It will take approximately 45 seconds or more.) ENG SPEED

Above 2,400 rpm

Vehicle speed

Above 90 km/h (56 MPH)

B/FUEL SCHDL

4.0 - 8.0 msec

Selector lever

4th or 5th

If “TESTING” is not displayed after 5 minutes, retry from step 2. 8) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-249. With GST 1) Turn ignition switch “ON”.

EC-246

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure (Cont’d)

2)

3)

4)

Check engine coolant temperature in MODE 1 with GST. Engine coolant temperature: Less than 40°C (104°F) If the value is out of range, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to lower the coolant temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. Start engine and let it idle monitoring the value of “COOLAN TEMP/S”. When the engine coolant temperature reaches 70°C (158°F), immediately go to the next step. Maintain the following conditions for at least 1 minute.

Engine speed

Above 2,400 rpm

Vehicle speed

Above 90 km/h (56 MPH)

Selector lever

4th or 5th

5) 6) 7) 8) 9) I

Stop vehicle. Turn ignition switch “OFF” and wait at least 9 seconds, then turn “ON”. Repeat step 2 to 4. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-249. When using GST, “DTC CONFIRMATION PROCEDURE” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.

EC-247

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Wiring Diagram

Wiring Diagram

EC-248

NCEC0231

YEC072A

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0232

CHECK EXHAUST SYSTEM

1. Start engine. 2. Check exhaust pipes and muffler for leaks.

SEF099P

OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Repair or replace exhaust system.

2

CHECK POWER SUPPLY

1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

DISCONNECT

SEF556WA

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.

EC-249

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure (Cont’d)

3

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit, short to ground or short to power in harness connectors.

4

CHECK EGR PASSAGE

Check EGR passage for clogging and cracks. OK or NG OK

©

GO TO 5.

NG

©

Repair or replace EGR passage.

5

CHECK EGR TEMPERATURE SENSOR

Refer to “TROUBLE DIAGNOSIS FOR DTC P1401”, EC-QG-300. OK or NG OK

©

GO TO 6.

NG

©

Replace EGR temperature sensor.

6

CHECK EGR VOLUME CONTROL VALVE

Refer to “Component Inspection”, EC-QG-251. OK or NG OK

©

GO TO 7.

NG

©

Replace EGR volume control valve.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-250

DTC P0400 EGR FUNCTION (CLOSE) (IF SO EQUIPPED) QG16I18DE Component Inspection

Component Inspection

NCEC0233

EGR VOLUME CONTROL VALVE

NCEC0233S01

With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6

SEF069X

3) 4)

5) 6)

1) 2)

SEF558W

3)

Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening. If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.

NEF109A

SEF560W

EC-251

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Description

Description

NCEC0504

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

ECM function

EGR control

NCEC0504S01

Actuator

EGR volume control valve

Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Battery

Battery voltage

This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains closed under the following conditions. I Low engine coolant temperature I Engine starting I High-speed engine operation I Extremely light load engine operation I Engine idling I Excessively high engine coolant temperature I Wide open throttle I Mass air flow sensor malfunction I Low battery voltage

SEF551W

COMPONENT DESCRIPTION

NCEC0504S02

The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W

EC-252

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0506

Specification data are reference values. MONITOR ITEM

EGR VOL CON/V

CONDITION I Engine: After warming up I Shift lever: “N” I No-load

SPECIFICATION

Idle

0 step

Revving engine up to 3,000 rpm quickly

10 - 55 step

ECM Terminals and Reference Value

NCEC0507

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO. 8 9 17 18

W/B SB G/R R/Y

ITEM

EGR volume control valve

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm

0 - 14V

On Board Diagnosis Logic DTC No. P0403 0403

Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.

Check Items (Possible Cause) I Harness or connectors (The EGR volume control valve circuit is open or shorted.) I EGR volume control valve

DTC Confirmation Procedure

NEF110A

NCEC0508

NCEC0509

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to 2,000 rpm 20 times.

EC-253

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) DTC Confirmation Procedure (Cont’d)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-256. With GST Follow the procedure “With CONSULT-II” above.

EC-254

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Wiring Diagram

Wiring Diagram

NCEC0510

BATTERY : Detectable line for DTC Refer to EL-POWER.

: Non-detectable line for DTC

EGR VOLUME CONTROL VALVE

ECM RELAY

ECM

EC-255

YEC782

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Diagnostic Procedure

Diagnostic Procedure 1

NCEC0511

CHECK POWER SUPPLY

1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SEF556W

Voltage: Battery voltage OK or NG OK

©

GO TO 2.

NG

©

Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.

2

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit, short to ground or short to power in harness connectors.

3

CHECK EGR VOLUME CONTROL VALVE

Refer to “Component Inspection”, EC-QG-257. OK or NG OK

©

GO TO 4.

NG

©

Replace EGR volume control valve.

4

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-256

DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT) QG16I18DE (IF SO EQUIPPED) Component Inspection

Component Inspection

NCEC0512

EGR VOLUME CONTROL VALVE

NCEC0512S01

With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6

SEF069X

3) 4)

5) 6)

1) 2)

SEF558W

3)

Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening. If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.

NEF109A

SEF560W

EC-257

DTC P0420 THREE WAY CATALYST FUNCTION

QG16I18DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NLEC0240

The ECM monitors the switching frequency ratio of heated oxygen sensors 1 (front) and 2 (rear). A three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2 (rear). As oxygen storage capacity decreases, the heated oxygen sensor 2 (rear) switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 (front) and 2 (rear) approaches a specified limit value, the three way catalyst malfunction is diagnosed. SEF184UD

DTC No. P0420 0420

Malfunction is detected when ... I Three way catalyst does not operate properly. I Three way catalyst does not have enough oxygen storage capacity.

Check Items (Possible Cause) I I I I I I I

Three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing

DTC Confirmation Procedure

SEF847Y

SEF848Y

NLEC0241

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II TESTING CONDITION: I Open engine hood before conducting following procedure. I Do not hold engine speed more than specified minutes below. 1) Turn ignition switch “ON”. 2) Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 3,000±500 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. If “COMPLETED” appears on the CONSULT-II screen, go to step 7. 5) Wait 5 seconds at idle. 6) Rev engine up to 2,500±500 rpm and maintain it until “INCMP” of CATALYST changes to “CMPLT” (it will take approximately 5 minutes.) If not “CMPLT”, stop engine and cool it down to less than 70°C (158°F) and then retest from step 1. 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. 8) Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-259.

SEF560X

EC-258

DTC P0420 THREE WAY CATALYST FUNCTION

QG16I18DE Overall Function Check

Overall Function Check

SEF074X

Diagnostic Procedure 1

NCEC0242

Use this procedure to check the overall function of the three way catalyst. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeters probes between ECM terminals 62 (HO2S1 signal), 63 (HO2S2 signal) and engine ground. 4) Keep engine speed at 2,000 rpm constant under no load. 5) Make sure that the voltage switching frequency (high & low) between ECM terminal 63 and engine ground is much less than that of ECM terminal 62 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 (rear) voltage switching frequency B: Heated oxygen sensor 1 (front) voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means three way catalyst does not operate properly. NOTE: If the voltage at terminal 62 does not switch periodically more than 5 times within 10 seconds at step 4, perform trouble diagnosis for DTC P0133 first. (See EC-QG-155.)

NCEC0243

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent. OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

2

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.

SEF099P

OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

EC-259

DTC P0420 THREE WAY CATALYST FUNCTION

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK IGNITION TIMING

Check for ignition timing. Refer to TROUBLE DIAGNOSIS — “BASIC INSPECTION”, EC-QG-72. OK or NG OK

©

GO TO 5.

NG

©

Check camshaft position sensor (PHASE) (EC-QG-238) and crankshaft position sensor (POS) (EC-QG-232).

5

CHECK INJECTORS

1. Refer to Wiring Diagram for Injectors, EC-QG-319. 2. Stop engine and then turn ignition switch “ON”. 3. Check voltage between ECM terminals 101, 103, 105 and 107 and ground with CONSULT-II or tester.

SEF075X

Battery voltage should exist. OK or NG OK

©

GO TO 6.

NG

©

Perform “Diagnostic Procedure” INJECTOR, EC-QG-320.

EC-260

DTC P0420 THREE WAY CATALYST FUNCTION

QG16I18DE

Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK IGNITION SPARK Disconnect ignition coil assembly from rocker cover. Connect a known good spark plug to the ignition coil assembly. Place end of spark plug against a suitable ground and crank engine. Check for spark.

SEF575Q

OK or NG OK

©

GO TO 7.

NG

©

Check ignition coil, power transistor and their circuits. Refer to EC-QG-323.

7

CHECK INJECTOR

1. Turn ignition switch “OFF”. 2. Remove injector assembly. Refer to EC-QG-30. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect camshaft position sensor harness connector. 4. Turn ignition switch “ON”. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)

©

GO TO 8.

NG (Drips)

©

Replace the injector(s) from which fuel is dripping.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

Trouble is fixed

©

INSPECTION END

Trouble is not fixed

©

Replace three way catalyst.

EC-261

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Description

Description

NCEC0248

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage

Ignition switch

Start signal

Throttle position sensor

Throttle position

Heated oxygen 1 sensor

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

NCEC0248S01

ECM function

EVAP canister purge control

Actuator

EVAP canister purge volume control solenoid valve

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes.

COMPONENT DESCRIPTION

NCEC0248S02

The EVAP canister purge volume control solenoid valve uses a ON/OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve.

SEF337U

CONSULT-II Reference Value in Data Monitor Mode

NCEC0249

MONITOR ITEM

PURG VOL C/V

CONDITION I Engine: After warming up I No-load I Lift up drive wheels and shift to 1st gear position. I Air conditioner switch “OFF”

SPECIFICATION

Idle

0%

More than 2,000 rpm

—

EC-262

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) ECM Terminals and Reference Value

ECM Terminals and Reference Value

NCEC0250

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

14

P/B

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

BATTERY VOLTAGE (11 - 14V)

EVAP canister purge volume control solenoid valve [Vehicle is running] I Warm-up condition I 2,000 rpm

5 - 12V

On Board Diagnosis Logic DTC No. P0443 0443

Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.

NCEC0251

Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EVAP canister purge volume control solenoid valve

DTC Confirmation Procedure

NCEC0252

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-265. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)

NEF068A

EC-263

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Wiring Diagram

Wiring Diagram

NCEC0253

: Detectable line for DTC

IGNITION SWITCH ON or START

: Non-detectable line for DTC FUSE BLOCK (J/B)

Refer to EL-POWER.

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

ECM

Refer to last page (Foldout page)

EC-264

YEC783

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Diagnostic Procedure

Diagnostic Procedure 1

NCEC0254

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector.

SEF076X

3. Turn ignition switch “ON”. 4. Check voltage between terminals 2 and engine ground with CONSULT-II or tester.

SEF077X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 I 10A fuse I Harness for open or short between EVAP canister purge volume control valve and fuse

©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 14 and terminal 1. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-265

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL QG16I18DE SOLENOID VALVE (CIRCUIT) Diagnostic Procedure (Cont’d)

4

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Refer to “Component Inspection” EC-QG-266. OK or NG OK

©

GO TO 5.

NG

©

Replace EVAP canister purge volume control solenoid valve.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0255

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

NEF111A

NCEC0255S01

With CONSULT-II 1) Start engine. 2) Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. If OK, inspection end. If NG, go to following step. 3) Check air passage continuity. Condition PURG VOL CONT/V value

Air passage continuity between A and B

100.0%

Yes

0.0%

No

If NG, replace the EVAP canister purge volume control solenoid valve. Without CONSULT-II Check air passage continuity. SEF079X

Condition

Air passage continuity between A and B

12V direct current supply between terminals

Yes

No supply

No

If NG or operation takes more than 1 second, replace solenoid valve.

EC-266

QG16I18DE

DTC P0500 VEHICLE SPEED SENSOR (VSS)

Component Description

Component Description

NCEC0272

MODELS WITH VEHICLE SPEED SENSOR The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.

MODELS WITHOUT VEHICLE SPEED SENSOR The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM. SEF080X

ECM Terminals and Reference Value

NCEC0273

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 2.0 - 3.0 V

86

OR/W

[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W

On Board Diagnosis Logic DTC No. P0500 0500

Malfunction is detected when ... I The almost 0 km/h (0 MPH) signal from vehicle speed sensor or ABS actuator and electric unit (control unit) is sent to ECM even when vehicle is being driven.

NCEC0274

Check Items (Possible Cause) Models with vehicle speed sensor I Harness or connector (The vehicle speed sensor circuit is open or shorted.) I Vehicle speed sensor Models without vehicle speed sensor I Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) I ABS actuator and electric unit (control unit)

DTC Confirmation Procedure

NCEC0275

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: This procedure may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-267

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE

DTC Confirmation Procedure (Cont’d)

1) 2)

3)

NEF112A

4) 5) 6)

With CONSULT-II Start engine Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-QG-271. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 10 consecutive seconds.

ENG SPEED

2,600 - 4,000 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

6.0 - 11.7 msec

Selector lever

Suitable position

PW/ST SIGNAL

OFF

7)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-271. With GST Follow the procedure “With CONSULT-II” above.

EC-268

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0277

MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START

BATTERY

: Detectable line for DTC FUSE BLOCK (J/B)

: Non-detectable line for DTC

Refer to EL-POWER.

COMBINATION METER (SPEEDOMETER)

VEHICLE SPEED SENSOR

ECM

Refer to last page (Foldout page)

YEC784

EC-269

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE

Wiring Diagram (Cont’d)

MODELS AFTER VIN - P11U0548750

YEC073A

EC-270

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure

NCEC0278

MODELS BEFORE VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 9. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 and M52, F103 I Harness for open or short between combination meter and vehicle speed sensor

©

5

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-271

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE

Diagnostic Procedure (Cont’d)

MODELS WITH VSS AFTER VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104, F73, E90 and M52, F103 I Harness for open or short between combination meter and vehicle speed sensor

©

5

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-272

DTC P0500 VEHICLE SPEED SENSOR (VSS)

QG16I18DE

Diagnostic Procedure (Cont’d)

MODELS WITHOUT VSS AFTER VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between combination meter and ABS actuator and electric unit (control unit)

©

5

Repair harness or connectors. Check ABS actuator and electric unit (control unit) and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-273

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE

Description

Description

NCEC0279

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

PNP switch

Park/Neutral position

Air conditioner switch

Air conditioner operation

Power steering oil pressure switch

Power steering load signal

Battery

Battery voltage

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Cooling fan

Cooling fan operation

Electrical load

Electrical load signal

NCEC0279S01

ECM function

Actuator

Idle air conIACV-AAC valve trol

This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve changes the opening of the air by-pass passage to control the amount of auxiliary air. This valve is actuated by a step motor built into the valve, which moves the valve in the axial direction in steps corresponding to the ECM output signals. One step of IACV-AAC valve movement causes the respective opening of the air by-pass passage. (i.e. when the step advances, the opening is enlarged.) The opening of the valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM then controls the step position of the IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warm up, deceleration, and engine load (air conditioner, power steering, cooling fan operation and electrical load).

COMPONENT DESCRIPTION

NCEC0279S02

The IACV-AAC valve is operated by a step motor for centralized control of auxiliary air supply. This motor has four winding phases and is actuated by the output signals of ECM which turns ON and OFF two windings each in sequence. Each time the IACV-AAC valve opens or closes to change the auxiliary air quantity, the ECM sends a pulse signal to the step motor. When no change in the auxiliary air quantity is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF937W

EC-274

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0280

MONITOR ITEM

CONDITION I I I I

IACV-AAC/V

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

5 - 20 steps

2,000 rpm

—

ECM Terminals and Reference Value

NCEC0281

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 7 15 16

WIRE COLOR BR Y/B P OR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

IACV-AAC valve

0.1 - 14V

On Board Diagnosis Logic DTC No. P0505 0505

Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.

Check Items (Possible Cause) I Harness or connectors (The IACV-AAC valve circuit is open.) I IACV-AAC valve

DTC Confirmation Procedure

NEF085A

NCEC0282

NCEC0283

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. If the target idle speed is out of the specified value, perform “Idle Air Volume Learning”, EC-QG-33, before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to “Service Data and Specifications (SDS)”, EC-QG-355. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to more than 2,000 rpm 20 times. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-277. With GST Follow the procedure “With CONSULT-II” above.

EC-275

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0284

BATTERY : Detectable line for DTC : Non-detectable line for DTC

Refer to EL-POWER.

IACV-AAC VALVE ECM RELAY

ECM

YEC785

EC-276

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0285

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect IACV-AAC valve harness connector. Throttle body

Throttle position sensor harness connector

IACV-AAC valve harness connector NEF246A

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2, 5 and ground with CONSULT-II or tester.

Voltage: Battery voltage

SEF352QA

OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between IACV-AAC valve and battery ©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 6 and IACV-AAC valve terminal 1, ECM terminal 7 and IACV-AAC valve terminal 4, ECM terminal 15 and IACV-AAC valve terminal 3, ECM terminal 16 and IACV-AAC valve terminal 6. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-277

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4.

CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-I Reconnect the ECM harness connector and IACV-AAC valve harness connector. Disconnect the vacuum hose connected to the air control valve (Power steering) at the intake air duct. Start engine and let it idle. Check vacuum hose for vacuum existence.

SEF162Z

Vacuum does not exist or slightly exist. OK or NG OK

©

GO TO 5.

NG

©

Replace air control valve (Power steering).

5

CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-II

Check the vacuum hose for vacuum existence when steering wheel is turned.

SEF162Z

Vacuum should exist. OK or NG OK

©

GO TO 8.

NG

©

GO TO 6.

EC-278

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE

Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK VACUUM PORT Stop engine. Disconnect the vacuum hose connected to the air control valve (Power steering) at the vacuum port. Blow air into vacuum port. Check that air flows freely.

SEF924Y

OK or NG OK

©

GO TO 7.

NG

©

Repair or clean vacuum port.

7

CHECK VACUUM HOSES AND TUBES

1. Disconnect vacuum hoses between the air control valve (Power steering) and vacuum port, air control valve (Power steering) and air duct. 2. Check hoses and tubes for cracks, clogging, improper connection or disconnection.

SEF109L

OK or NG OK

©

GO TO 8.

NG

©

Repair hoses or tubes.

8

CHECK IACV-AAC VALVE

Refer to “Component Inspection”, EC-QG-281. OK or NG OK

©

GO TO 10.

NG

©

GO TO 9.

EC-279

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE Diagnostic Procedure (Cont’d)

9

REPLACE IACV-AAC VALVE

1. Replace IACV-AAC valve assembly. 2. Perform “Idle Air Volume Learning”, EC-QG-33. Is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

INSPECTION END

INCMP

©

Follow the instruction of “Idle Air Volume Learning”.

10

CHECK TARGET IDLE SPEED

1. Turn ignition switch “OFF”. 2. Reconnect all harness connectors and vacuum hoses. 3. Start engine and warm it up to normal operating temperature. 4. Also warm up transmission to normal operating temperature. I Drive vehicle for 10 minutes. 5. Stop vehicle with engine running. 6. Check target idle speed. 700±50 rpm OK or NG OK

©

GO TO 11.

NG

©

Perform “Idle Air Volume Learning”, EC-QG-33.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-280

QG16I18DE

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

QG16I18DE Component Inspection

Component Inspection

NCEC0286

IACV-AAC VALVE 1) 2)

NCEC0286S01

Disconnect IACV-AAC valve harness connector. Check IACV-AAC valve resistance. Condition

Resistance

Terminal 2 and terminals 1, 3 20 - 24Ω [at 20°C (68°F)] Terminal 5 and terminals 4, 6

3) 4)

5)

Reconnect IACV-AAC valve harness connector. Remove idle air adjusting unit assembly (IACV-AAC valve is built-in) from engine. (The IACV-AAC valve harness connector should remain connected.) Turn ignition switch “ON” and “OFF”, and ensure the IACVAAC valve shaft smoothly moves forward and backward, according to the ignition switch position. If NG, replace the IACV-AAC valve.

SEF353QA

SEF089X

EC-281

QG16I18DE

DTC P0605 ECM Component Description

Component Description

NCEC0295

The ECM consists of a microcomputer, diagnostic test mode selector, and connectors for signal input and output and for power supply. The ECM controls the engine.

SEF093X

DTC No. P0605 0605

On Board Diagnosis Logic

Malfunction is detected when ... I ECM calculation function is malfunctioning.

Check Items (Possible Cause) I ECM

DTC Confirmation Procedure

NEF068A

NCEC0297

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine. 4) Run engine for at least 1 second at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-282. With GST Follow the procedure “With CONSULT-II” above.

Diagnostic Procedure 1

NCEC0296

INSPECTION START

With CONSULT-II Turn ignition switch “ON”. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.

With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.

Yes or No Yes

©

GO TO 2.

No

©

INSPECTION END

EC-282

=NCEC0298

DTC P0605 ECM

QG16I18DE Diagnostic Procedure (Cont’d)

2

REPLACE ECM

1. Replace ECM. 2. Perform initialization of NATS (NISSAN ANTI-THEFT SYSTEM) system and registration of all NATS ignition key IDs. Refer to “NATS (NISSAN ANTI-THEFT SYSTEM)”, EC-QG-45. 3. Perform “Idle Air Volume Learning”, EC-QG-33. Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

INSPECTION END

INCMP

©

Follow the construction of “Idle Air Volume Learning”.

EC-283

DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE

QG16I18DE

Component Description

Component Description

NCEC0513

The valve timing control system is utilized to control intake valve opening and closing timing. Engine coolant temperature signals, engine speed and throttle position are used to determine intake valve timing. The intake camshaft sprocket position is regulated by oil pressure controlled by the intake valve timing control. When ECM sends ON signal to intake valve timing control solenoid valve, oil pressure is transmitted to camshaft sprocket. Then, intake side camshaft is advanced. SEF095X

Operation

NCEC0514

Engine operating condition Engine coolant temperature

Engine speed

20°C (68°F) 70°C (158°F)

B/FUEL SCHDL

Intake valve opening and closing time

Valve overlap

Neutral switch

Intake valve timing control solenoid valve

OFF

ON

Advance

Increased

OFF

Normal

Normal

Above 3 msec 1,150 - 4,600 rpm

Above 70°C (158°F)

Above 7 msec Conditions other than those above

CONSULT-II Reference Value in Data Monitor Mode

NCEC0515

MONITOR ITEM

INT/V SOL-B1

CONDITION

I Engine: After warming up

SPECIFICATION

Idle

OFF

Revving engine with full throttle opening (Under 4,600 rpm)

ON

ECM Terminals and Reference Value

NCEC0516

Specification data are reference values and are measured between each terminal and engine ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERWIRE MINAL COLOR NO. 1

Y/R

ITEM Intake valve timing control solenoid valve

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

Ignition “ON”

On Board Diagnosis Logic DTC No. P1111 1111

Malfunction is detected when ... I An improper voltage signal is entered to ECM through intake valve timing control solenoid valve.

EC-284

NCEC0517

Check Items (Possible Cause) I Harness or connectors (The intake valve timing control solenoid valve circuit is open or shorted.) I Intake valve timing control solenoid valve

DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE

QG16I18DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NEF121A

NCEC0518

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-287. Without CONSULT-II Follow the procedure “With CONSULT-II” above.

EC-285

DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0519

IGNITION SWITCH ON or START

: Detectable line for DTC : Non-detectable line for DTC FUSE BLOCK (J/B)

Refer to EL-POWER.

INTAKE VALVE TIMING CONTROL SOLENOID VALVE

.

IVC ECM

Refer to last page (Foldout page)

EC-286

YEC787

DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0520

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect intake valve timing control solenoid valve harness connector.

SEF149X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and engine ground with CONSULT-II or tester.

SEF097X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connector F104, M50 I 10A fuse I Harness for open or short between intake valve timing control solenoid valve and fuse

©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 1 and intake valve timing control solenoid valve harness connector terminal 1. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground to short to power or connectors.

EC-287

DTC P1111 INTAKE VALVE TIMING CONTROL SOLENOID VALVE

QG16I18DE

Diagnostic Procedure (Cont’d)

4

CHECK VALVE TIMING CONTROL SOLENOID VALVE

Refer to “Component Inspection”, EC-QG-288. OK or NG OK

©

GO TO 5.

NG

©

Replace valve timing control solenoid valve.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Intake valve timing control solenoid valve

Component Inspection

NCEC0521

INTAKE VALVE TIMING CONTROL SOLENOID VALVE NCEC0521S01 1. 2. 3.

Check oil passage visually for any metal debris. Supply intake valve timing control solenoid valve terminals with battery voltage. Make sure that inside plunger protrudes. If NG, replace intake valve timing control solenoid valve.

Plunger FUSE SEF524T

EC-288

QG16I18DE

DTC P1217 OVERHEAT (COOLING SYSTEM)

System Description

System Description

NCEC0433

COOLING FAN CONTROL

NCEC0433S01

Sensor

ECM function

Input Signal to ECM

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner “ON” signal

Ignition switch

Start signal

Refrigerant pressure sensor

Refrigerant pressure

Actuator

Cooling fan Cooling fan relay(s) control

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has ON-OFF control. The refrigerant pressure sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The transducer is installed in the liquid tank of the air conditioner system.

SEF099X

OPERATION

NCEC0433S02

Engine coolant temperatures at which the cooling fan turns “ON” are indicated in the Table below. Vehicle speed km/h (MPH) Air conditioner switch

ON

High pressure of refrigerant kPa (bar, kg/cm2, psi)

Less than 20 (12)

20 - 80 (12 - 50)

More than 80 (50)

More than 1,760 (17.6, 17.95, 255)

Always

Always

More than 95°C (203°F)

Less than 1,760 (17.6, 17.95, 255)

Always

More than 95°C (203°F)

More than 95°C (203°F)

More than 100°C (212°F)

More than 95°C (203°F)

More than 95°C (203°F)

OFF

CONSULT-II Reference Value in Data Monitor Mode

NCEC0486

Specification data are reference values. MONITOR ITEM

AIR COND SIG

COOLING FAN

CONDITION I Engine: After warming up, idle the engine

I After warming up engine, idle the engine. I Air conditioner switch: OFF

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON (Compressor operates)

ON

Engine coolant temperature is less OFF than 99°C (210°F) Engine coolant temperature is 100°C (212°F) or more

EC-289

ON

QG16I18DE

DTC P1217 OVERHEAT (COOLING SYSTEM) ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NCEC0487

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

13

23

LG/R

L/W

ITEM

Cooling fan relay

Air conditioner switch

CONDITION

DATA (DC Voltage)

[Engine is running] I Cooling fan is not operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Cooling fan is operating

Approximately 0V

[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)

Approximately 0V

[Engine is running] I Air conditioner switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic

NCE0488

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. Diagnostic Trouble Code No. P1217 1217

Malfunction is detected when ...

Check Items (Possible Cause)

I Cooling fan does not operate properly (Overheat). I Harness or connectors I Cooling fan system does not operate properly (Overheat). (The cooling fan circuit is open or shorted). I Engine coolant was not added to the system using the I Cooling fan proper filling method. I Radiator hose I Radiator I Radiator cap I Water pump I Thermostat For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-QG-298.

CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil. 1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-290

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE Overall Function Check

Overall Function Check

SEF621WA

SEF111X

SEC163BA

NCEC0489

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. With CONSULT-II 1) Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 3) Turn ignition switch “ON”. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. 5) If the results are NG, go to “Diagnostic Procedure”, EC-QG294. Without CONSULT-II 1) Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-QG-294. 3) Start engine. Be careful not to overheat engine. 4) Set temperature control lever to full cold position. 5) Turn air conditioner switch “ON”. 6) Turn blower fan switch “ON”. 7) Run engine at idle for a few minutes with air conditioner operating. Be careful not to overheat engine. 8) Make sure that cooling fan operates. If NG, go to “Diagnostic Procedure”, EC-QG-294.

EC-291

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Wiring Diagram

Wiring Diagram IGNITION SWITCH ON or START

NCEC0490

BATTERY : Detectable line for DTC FUSE BLOCK (J/B)

: Non-detectable line for DTC Refer to EL-POWER.

COOLING FAN RELAY

COOLING FAN MOTOR-1

COOLING FAN MOTOR-2

Refer to last page (Foldout page)

EC-292

YEC789

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE Wiring Diagram (Cont’d)

REFRIGERANT SENSOR

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC790

EC-293

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

NCEC0491

CHECK COOLING FAN OPERATION Start engine and let it idle. Set temperature lever at full cold position. Turn air conditioner switch “ON”. Turn blower fan switch “ON”. Make sure that cooling fans-1 and -2 operate.

SEC163BA

OK or NG OK

©

GO TO 11.

NG

©

GO TO 2.

2

CHECK AIR CONDITIONER OPERATION

Is air conditioner operating? (Check operation of compressor and blower motor.) OK or NG OK

©

GO TO 3.

NG

©

Check for failure of air conditioner to operate. Refer to HA section.

3 1. 2. 3. 4.

CHECK POWER SUPPLY Turn ignition switch “OFF”. Disconnect cooling fan relay. Turn ignition switch “ON”. Check voltage between terminals 2, 3 and ground with CONSULT-II or tester.

SEF112X

Voltage: Battery voltage OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-294

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M70, E125 I 10A fuse I 40A fusible link I Harness for open or short between cooling fan relay and fuse I Harness for open or short between cooling fan relay and battery

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect cooling fan motor-1 harness connector and cooling fan motor-2 harness connector.

SEF113X

3. Check harness continuity between relay terminal 5 and motor-1 terminal 1, motor-1 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. 5. Check harness continuity between relay terminal 5 and motor-2 terminal 1, motor-2 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 6. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK OUTPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 13 and relay terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E42, F4 I Harness for open or short between cooling fan relay and ECM

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-295

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Diagnostic Procedure (Cont’d)

8

CHECK COOLING FAN RELAY

Refer to “Component Inspection”, EC-QG-299. OK or NG OK

©

GO TO 9.

NG

©

Replace cooling fan relay.

9

CHECK COOLING FAN MOTORS-1 AND -2

Refer to “Component Inspection”, EC-QG-299. OK or NG OK

©

GO TO 10.

NG

©

Replace cooling fan motors.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

11

INSPECTION END

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

SLC754A

Pressure should not drop. OK or NG OK

©

GO TO 12.

NG

©

Check the following for leak I Hose I Radiator I Water pump Refer to LC section (“Water Pump”).

EC-296

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Diagnostic Procedure (Cont’d)

12

CHECK RADIATOR CAP

Apply pressure to cap with a tester.

SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK

©

GO TO 13.

NG

©

Replace radiator cap.

13

CHECK THERMOSTAT

1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.

Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). OK or NG OK

©

GO TO 14.

NG

©

Replace thermostat

14

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-QG-124. OK or NG OK

©

GO TO 15.

NG

©

Replace engine coolant temperature sensor.

15

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-QG-298. ©

INSPECTION END

EC-297

SLC343

DTC P1217 OVERHEAT (COOLING SYSTEM)

QG16I18DE

Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

Inspection item

OFF

1

I I I I

2

Equipment

Standard

NCEC0492

Reference page

I Visual

No blocking

I Coolant mixture

I Coolant tester

50 - 50% coolant mixture

See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.

3

I Coolant level

I Visual

Coolant up to MAX level in reservoir tank and radiator filler neck

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.

4

I Radiator cap

I Pressure tester

59 - 98 kPa See “System Check”, (0.59 - 0.98 bar, 0.6 - 1.0 “ENGINE COOLING kg/cm2, 9 - 14 psi) (Limit) SYSTEM” in LC section.

ON*2

5

I Coolant leaks

I Visual

No leaks

ON*2

6

I Thermostat

I Touch the upper and lower radiator hoses

Both hoses should be hot See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.

ON*1

7

I Cooling fan

I CONSULT-II

Operating

OFF

8

I Combustion gas leak

I Color checker chemical Negative tester 4 Gas analyzer

—

ON*3

9

I Coolant temperature gauge

I Visual

Gauge less than 3/4 when driving

—

I Coolant overflow to reservoir tank

I Visual

No overflow during driving and idling

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

—

See “System Check”, “ENGINE COOLING SYSTEM” in LC section.

See “TROUBLE DIAGNOSIS FOR OVERHEAT” (EC-QG-289).

OFF*4

10

I Coolant return from reservoir tank to radiator

I Visual

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

11

I Cylinder head

I Straight gauge feeler gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

12

I Cylinder block and pis- I Visual tons

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

*1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.

EC-298

QG16I18DE

DTC P1217 OVERHEAT (COOLING SYSTEM)

Component Inspection

Component Inspection

NCEC0493

COOLING FAN RELAYS

NCEC0493S01

Check continuity between terminals 3 and 5. Conditions

SEF511P

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

If NG, replace relay.

COOLING FAN MOTORS-1 AND -2 1. 2.

NCEC0493S02

Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. Terminals

Cooling fan motor SEF721Q

(+)

(−)

1

2

Cooling fan motor should operate. If NG, replace cooling fan motor.

REFRIGERANT PRESSURE SENSOR

NCEC0493S03

With the refrigerant pressure sensor installed on the vehicle, start the engine and while idling, read the voltage at refrigerant pressure sensor terminals 1 and 2. (Refer to wiring diagram.) Air conditioner condition

Voltage V

OFF

More than approx. 0.3V

ON

More than approx. 1.5V

ON to OFF

Decreasing gradually

If results are NG, check for 5V between refrigerant sensor terminal 3 and ground. If there is 5V, replace sensor.

EC-299

DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)

QG16I18DE

Component Description

Component Description

NCEC0342

The EGR temperature sensor detects temperature changes in the EGR passageway. When the EGR volume control valve opens, hot exhaust gases flow, and the temperature in the passageway changes. The EGR temperature sensor is a thermistor that modifies a voltage signal sent from the ECM. This modified signal then returns to the ECM as an input signal. As the temperature increases, EGR temperature sensor resistance decreases. This sensor is not used to control the engine system. It is used only for the on board diagnosis. SEF599K

EGR temperature °C (°F)

Voltage* V

Resistance MΩ

0 (32)

4.56

0.62 - 1.05

50 (122)

2.25

0.065 - 0.094

100 (212)

0.59

0.011 - 0.015

*: These data are reference values and are measured between ECM terminal 72 (EGR temperature sensor) and ground. When EGR system is operating. Voltage: 0 - 1.5V

CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

SEF068X

On Board Diagnosis Logic DTC No. P1401 1401

Malfunction is detected when ...

NCEC0343

Check Items (Possible Cause)

A)

An excessively low voltage from the EGR temperature sensor is sent to ECM even when engine coolant temperature is low.

I Harness or connectors (The EGR temperature sensor circuit is shorted.) I EGR temperature sensor I Malfunction of EGR function

B)

An excessively high voltage from the EGR temperature sensor is sent to ECM even when engine coolant temperature is high.

I Harness or connectors (The EGR temperature sensor circuit is open.) I EGR temperature sensor I Malfunction of EGR function

DTC Confirmation Procedure

NCEC0344

Perform “PROCEDURE FOR MALFUNCTION A” first. If 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

EC-300

DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)

QG16I18DE

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION A

NEF113A

PROCEDURE FOR MALFUNCTION B

NEF114A

=NCEC0344S01

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Verify that engine coolant temperature is less than 50°C (122°F). If the engine coolant temperature is above the range, cool the engine down. 4) Start engine and let it idle for at least 5 seconds. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-303. With GST Follow the procedure “With CONSULT-II” above.

NCEC0344S02

CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: Always perform the test at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to above 80°C (176°F). 2) Select “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT. 3) Hold engine speed at 1,500 rpm. 4) Touch “Qu” and set the EGR volume control valve opening to 50 step and check EGR TEMP SEN. EGR TEMP SEN should decrease to less than 1.0V. If the check result is NG, go to “Diagnostic Procedure”, ECQG-303. If the check result is OK, go to the following step. 5) Turn ignition switch “OFF” and wait at least 9 seconds. 6) Start engine and maintain the following conditions for at least 5 consecutive seconds. ENG SPEED

Above 2,400 rpm

VHCL SPEED SE

Above 90 km/h (56 MPH) or more

B/FUEL SCHDL

4.0 - 4.8 msec

Selector lever

4th or 5th

7)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-303. With GST Follow the procedure “With CONSULT-II” above.

EC-301

DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0346

YEC074A

EC-302

DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)

QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0347

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect EGR temperature sensor harness connector.

SEF127X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF128X

Voltage: Approximately 5V OK or NG OK

©

GO TO 2.

NG

©

Repair harness or connectors.

2

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between EGR temperature sensor harness terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between EGR temperature sensor and ECM.

©

4

Repair open circuit or short to ground or short to power in harness or connector.

CHECK EGR TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-QG-304. OK or NG OK

©

GO TO 5.

NG

©

Replace EGR temperature sensor.

EC-303

DTC P1401 EGR TEMPERATURE SENSOR (IF SO EQUIPPED)

QG16I18DE

Diagnostic Procedure (Cont’d)

5

CHECK EGR VOLUME CONTROL VALVE

Refer to “Component Inspection”, EC-QG-251. OK or NG OK

©

GO TO 6.

NG

©

Replace EGR volume control valve.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection EGR TEMPERATURE SENSOR

NCEC0348 NCEC0348S01

Check resistance change and resistance value.

SEF643Q

EGR temperature °C (°F)

Voltage V

Resistance MΩ

0 (32)

4.56

0.62 - 1.05

50 (122)

2.25

0.065 - 0.094

100 (212)

0.59

0.011 - 0.015

If NG, replace EGR temperature sensor.

SEF068X

EC-304

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Description

Description

NCEC0349

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Battery

Battery voltage

NCEC0349S01

ECM function

Actuator

EGR control EGR volume control valve

This system controls flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR by-pass passage in the EGR volume control valve changes to control the flow rate. A built-in step motor moves the valve in steps corresponding to the ECM output pulses. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. The EGR volume control valve remains close under the following conditions. I Extremely light load engine operation I Mass air flow sensor malfunction I Engine idling I Low engine coolant temperature I Excessively high engine coolant temperature I High-speed engine operation I Wide open throttle I Low battery voltage I Engine starting

SEF551W

COMPONENT DESCRIPTION EGR Volume Control Valve

NCEC0349S02 NCEC0349S0201

The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF552W

EC-305

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0539

Specification data are reference values. MONITOR ITEM

CONDITION

EGR TEMP SEN

I Engine: After warming up

EGR VOL CON/V

I I I I

SPECIFICATION Less than 4.5V

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

0 step

Revving engine up to 3,000 rpm quickly

10 - 55 step

ECM Terminals and Reference Value

NCEC0540

Specification data are reference values, and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage)

8 9 17 18

W/B SB G/R R/Y

EGR volume control valve

[Engine is running.] I Warm-up condition I Rev engine up from 2,000 to 4,000 rpm.

0 - 14V

58

B

Sensor’s ground

[Engine is running.] I Warm-up condition I Idle speed

0V

[Engine is running.] I Warm-up condition I Idle speed

Less than 4.5V

[Engine is running.] I Warm-up condition I EGR system is operating.

0 - 1.0V

72

PU

EGR temperature sensor

On Board Diagnosis Logic

NCEC0350

If EGR temperature sensor detects EGR flow under the condition that does not call for EGR, a high-flow malfunction is diagnosed.

SEF073P

DTC No. P1402 1402

Malfunction is detected when ...

Check Items (Possible Cause)

I EGR flow is detected under conditions that do not call for I Harness or connectors EGR. (The valve circuit is open or shorted.) I EGR volume control valve leaking or stuck open I EGR temperature sensor

EC-306

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure

DTC Confirmation Procedure

PEF347U

NCEC0351

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Engine coolant temperature and EGR temperature must be verified in “DATA MONITOR” mode with CONSULT-II before starting DTC WORK SUPPORT test. If it is out of range below, the test cannot be conducted. COOLAN TEMP/S: −10 to 40°C (14 to 104°F)* EGR TEMP SEN: Less than 4.8V If the values are out of the ranges indicated above, park the vehicle in a cool place and allow the engine temperature to stabilize. Do not attempt to reduce the engine coolant or EGR temperature with a fan or means other than ambient air. Doing so may produce an inaccurate diagnostic result. *: Although CONSULT-II screen displays “−10 to 40°C (14 to 104°F)” as a range of engine coolant temperature, ignore it.

SEF127X

EC-307

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE DTC Confirmation Procedure (Cont’d)

1) 2) 3) 4)

NEF115A

5)

1) 2) 3) NEF116A

4) 5) 6) 7) 8)

With CONSULT-II Turn ignition switch “OFF” and wait at least 9 seconds, then turn ignition switch “ON”. Select “EGR SYSTEM P1402” of “EGR SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Follow instructions of CONSULT-II. Start engine and let it idle until “TESTING” on CONSULT-II screen is turned to “COMPLETED”. (It will take 45 seconds or more.) If “TESTING” is not displayed after 5 minutes, turn ignition “OFF” and cool the engine coolant temperature to the range of −10 to 40°C (14 to 104°F). Retry from step 1. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-QG-310. With GST Turn ignition switch “ON” and select “MODE 1” with GST. Check that engine coolant temperature is within the range of −10 to 40°C (14 to 104°F). Check that voltage between ECM terminal 72 (EGR temperature sensor signal) and ground is less than 4.8V. Start engine and let it idle for at least 45 seconds. Stop engine. Perform from step 1 to 4. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-QG-310.

PEF897U

EC-308

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Wiring Diagram

Wiring Diagram

EC-309

NCEC0352

YEC072A

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0353

CHECK POWER SUPPLY

1. Disconnect EGR volume control valve harness connector. 2. Turn ignition switch “ON”. 3. Check voltage between terminals 2, 5 and ground with CONSULT-II or tester.

SEF556W

Voltage: Battery voltage OK or NG OK

©

GO TO 2.

NG

©

Check the following. I Harness or connectors E90, F73 I Harness for open or short between EGR volume control valve and engine control module relay If NG, repair harness or connectors.

2

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 8 and EGR volume control valve terminal 1, ECM terminal 9 and EGR volume control valve terminal 4, ECM terminal 17 and EGR volume control valve terminal 3, ECM terminal 18 and EGR volume control valve terminal 6. Refer to wiring diagram. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit, short to ground or short to power in harness connectors.

3

CHECK EGR TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-QG-304. OK or NG OK

©

GO TO 4.

NG

©

Replace EGR temperature sensor.

4

CHECK EGR VOLUME CONTROL VALVE

Refer to “Component Inspection”, EC-QG-251. OK or NG OK

©

GO TO 5.

NG

©

Replace EGR volume control valve.

EC-310

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Diagnostic Procedure (Cont’d)

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection EGR TEMPERATURE SENSOR

NCEC0354 NCEC0354S01

Check resistance change and resistance value. EGR temperature °C (°F)

Voltage V

Resistance MΩ

0 (32)

4.56

0.62 - 1.05

50 (122)

2.25

0.065 - 0.094

100 (212)

0.59

0.011 - 0.015

SEF643Q

If NG, replace EGR temperature sensor.

SEF068X

EC-311

DTC P1402 EGR FUNCTION (OPEN) (IF SO EQUIPPED) QG16I18DE Component Inspection (Cont’d)

EGR VOLUME CONTROL VALVE

NCEC0354S04

With CONSULT-II 1) Disconnect EGR volume control valve harness connector. 2) Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

SEF069X

3) 4)

5) 6)

1) 2)

3) SEF558W

Reconnect EGR volume control valve harness connector. Remove EGR volume control valve from cylinder head. (The EGR volume control valve harness connector should remain connected.) Turn ignition switch “ON”. Perform “EGR VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening If NG, replace the EGR volume control valve. Without CONSULT-II Disconnect EGR volume control valve harness connector. Check resistance between the following terminals. terminal 2 and terminals 1, 3 terminal 5 and terminals 4, 6 Temperature °C (°F)

Resistance Ω

20 (68)

20 - 24

Turn ignition switch “ON” and “OFF”. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position. If NG, replace the EGR volume control valve.

NEF122A

SEF560W

EC-312

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Component Description

Component Description

NCEC0424

When the gear position is “N”, park/neutral position (PNP) switch is “ON”. ECM detects the park/neutral position when continuity with ground exists.

SEF740W

CONSULT-II Reference Value in Data Monitor Mode

NCEC0425

Specification data are reference values. MONITOR ITEM

CONDITION I Ignition switch: ON

P/N POSI SW

SPECIFICATION

Shift lever: “N”

ON

Except above

OFF

ECM Terminals and Reference Value

NCEC0426

Specification data are reference values, and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

42

WIRE COLOR

G/OR

ITEM

PNP switch

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] I Gear position is “Neutral position”

Approximately 0V

[Ignition switch “ON”] I Except the above gear position

Approximately 5V

On Board Diagnosis Logic DTC No. P1706 1706

Malfunction is detected when ... I The signal of the PNP switch is not changed in the process of engine starting and driving.

NCEC0427

Check Items (Possible Cause) I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch

DTC Confirmation Procedure

NCEC0428

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

EC-313

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE DTC Confirmation Procedure (Cont’d)

1) 2) 3) 4)

NEF118A

With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 50 consecutive seconds.

ENG SPEED

1,550 - 3,800 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

3.0 msec or more

VHCL SPEED SE

70 - 100 km/h (43 - 62 MPH)

Selector lever

Suitable position (Except “N” position)

5)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECQG-316.

Overall Function Check

NCEC0429

Use this procedure to check the overall function of the park/neutral position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch “ON”. 2) Check voltage between ECM terminal 42 (PNP switch signal) and body ground under the following conditions. Condition (Gear position)

SEF137X

Voltage (V) (Known good data)

“N” position

Approx. 0

Except the above position

Approx. 5

3)

If NG, go to “Diagnostic Procedure”, EC-QG-316.

EC-314

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0430

: Detectable line for DTC : Non-detectable line for DTC

PARK/NEUTRAL POSITION (PNP) SWITCH

EC-315

YEC791

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Diagnostic Procedure For M/T Models

Diagnostic Procedure For M/T Models 1

NCEC0431

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect PNP switch harness connector.

SEF740W

3. Check harness continuity between PNP switch harness connector terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between PNP switch and body ground.

©

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 42 and PNP switch harness connector terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and PNP switch.

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PNP SWITCH

Refer to MT section. OK or NG OK

©

GO TO 6.

NG

©

Replace PNP switch.

EC-316

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH QG16I18DE Diagnostic Procedure For M/T Models (Cont’d)

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-317

QG16I18DE

INJECTOR Component Description

Component Description

NCEC0435

The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the injector circuit, the coil in the injector is energized. The energized coil pulls the needle valve back and allows fuel to flow through the injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. SEF138X

CONSULT-II Reference Value in Data Monitor Mode

NCEC0436

MONITOR ITEM

INJ PULSE - B1

B/FUEL SCHDL

CONDITION

SPECIFICATION

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.2 msec

2,000 rpm

1.9 - 3.2 msec

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

1.5 - 2.5 msec

2,000 rpm

1.5 - 2.5 msec

ECM Terminals and Reference Value

NCEC0437

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Idle speed

101 103 105 107

R/B Y/B G/B L/B

Injector Injector Injector Injector

No. No. No. No.

1 2 3 4

SEF011W

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF012W

EC-318

QG16I18DE

INJECTOR

Wiring Diagram

Wiring Diagram

NCEC0434

IGNITION SWITCH ON or START : Detectable line for DTC FUSE BLOCK (J/B)

INJECTOR No.1

: Non-detectable line for DTC Refer to EL-POWER.

INJECTOR No.2

INJECTOR No.3

INJECTOR No.4

ECM

Refer to last page (Foldout page)

EC-319

YEC792

INJECTOR

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0438

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard. OK or NG OK

©

INSPECTION END

NG

©

GO TO 2.

EC-320

QG16I18DE

INJECTOR

Diagnostic Procedure (Cont’d)

2 1. 2. 3. 4.

CHECK POWER SUPPLY Stop engine. Disconnect injector harness connector. Turn ignition switch “ON”. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF986W

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. I 10A fuse I Harness connectors M50, F104 I Harness for open or short between injector and fuse

©

4

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between injector harness connector terminal 1 and ECM terminals 101, 103, 105, 107. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and injector.

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-321

INJECTOR

QG16I18DE

Diagnostic Procedure (Cont’d)

6

CHECK INJECTOR

Refer to “Component Inspection”, EC-QG-322. OK or NG OK

©

GO TO 7.

NG

©

Replace injector.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection INJECTOR 1. 2.

NCEC0439 NCEC0439S01

Disconnect injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 13.5 - 17.5Ω [at 25°C (77°F)] If NG, replace injector.

SEF139X

EC-322

QG16I18DE

IGNITION SIGNAL

Component Description

Component Description

NCEC0542

IGNITION COIL AND POWER TRANSISTOR

NCEC0542S01

The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns on and off the ignition coil primary circuit. This on-off operation induces the proper high voltage in the coil secondary circuit.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0543

Specification data are reference values. MONITOR ITEM IGNITION SW

CONDITION

SPECIFICATION

I Ignition switch: ON , OFF , ON

ON , OFF , ON

ECM Terminals and Reference Value

NCEC0544

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - 0.3V

[Engine is running] I Warm-up condition I Idle speed 35 36 37 38

Y/R PU/G L/Y GY/L

Ignition Ignition Ignition Ignition

signal signal signal signal

(No. (No. (No. (No.

1) 2) 3) 4)

SEF971W

0.2 - 0.4V

[Engine is running] I Engine speed is 2,000 rpm

SEF972W

EC-323

IGNITION SIGNAL

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0545

BATTERY : Detectable line for DTC Refer to EL-POWER. : Non-detectable line for DTC

ENGINE CONTROL MODULE RELAY

Next page

CONDENSER

Next page

EC-324

YEC793

QG16I18DE

IGNITION SIGNAL

Wiring Diagram (Cont’d)

Preceding page

IGNITION COIL No. 2 (WITH POWER TRANSISTOR)

IGNITION COIL No. 4 (WITH POWER TRANSISTOR)

SPARK PLUG

SPARK PLUG

IGNITION COIL No. 1 (WITH POWER TRANSISTOR)

IGNITION COIL No. 3 (WITH POWER TRANSISTOR)

SPARK PLUG

SPARK PLUG

Preceding page

: Detectable line for DTC : Non-detectable line for DTC

YEC794

EC-325

IGNITION SIGNAL

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0546

INSPECTION START

Turn ignition switch “OFF”, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)

©

GO TO 2.

Yes (Without CONSULT-II)

©

GO TO 3.

No

©

GO TO 4.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 2. Make sure that all circuits do not produce a momentary engine speed drop.

SEF190Y

OK or NG OK

©

INSPECTION END

NG

©

GO TO 13.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminals 35, 36, 37, 38 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below.

NEF236A

OK or NG OK

©

INSPECTION END

NG

©

GO TO 13.

EC-326

QG16I18DE

IGNITION SIGNAL

Diagnostic Procedure (Cont’d)

4

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I

1. Turn ignition switch ON. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.

SEF366X

OK or NG OK

©

GO TO 5.

NG

©

Go to TROUBLE DIAGNOSIS FOR POWER SUPPLY, EC-QG-103.

5 1. 2. 3. 4.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II Turn ignition switch OFF. Disconnect condenser harness connector. Turn ignition switch ON. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester.

SEF367X

OK or NG OK

©

GO TO 11.

NG

©

GO TO 6.

EC-327

IGNITION SIGNAL

QG16I18DE

Diagnostic Procedure (Cont’d)

6

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III

1. Turn ignition switch OFF. 2. Disconnect ECM relay.

SEF984W

3. Check harness continuity between ECM relay terminal 7 and condenser terminal 1. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F73, E90 I Harness for open or short between ECM relay and condenser ©

8

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV

1. Check voltage between ECM relay terminal 6 and ground with CONSULT-II or tester.

SEF368X

OK or NG OK

©

GO TO 10.

NG

©

GO TO 9.

9

DETECT MALFUNCTIONING PART

Check the following. I 15A fuses I Harness for open and short between ECM relay and fuse ©

Repair or replace harness or connectors.

EC-328

IGNITION SIGNAL

QG16I18DE Diagnostic Procedure (Cont’d)

10

CHECK ECM RELAY

1. Apply 12V direct current between ECM relay terminals 1 and 2. 2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.

SEF296X

OK or NG OK

©

GO TO 18.

NG

©

Replace ECM relay.

11

CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between condenser terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 12.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

12

CHECK CONDENSER

Refer to “Component Inspection”, EC-QG-331.

SEF369X

OK or NG OK

©

GO TO 13.

NG

©

Replace condenser.

EC-329

IGNITION SIGNAL

QG16I18DE

Diagnostic Procedure (Cont’d)

13 1. 2. 3. 4. 5.

CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V Turn ignition switch OFF. Reconnect harness connectors disconnected. Disconnect ignition coil harness connector. Turn ignition switch ON. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester.

NEF237A

Voltage: Battery voltage OK or NG OK

©

GO TO 15.

NG

©

GO TO 14.

14

DETECT MALFUNCTIONING PART

Check the harness for open or short ignition coil harness connector F73. ©

15

Repair or replace harness or connectors.

CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF. 2. Check harness continuity between ignition coil terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 16.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

16

CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminals 35, 36, 37, 38 and ignition coil terminal 3. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 17.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

17

CHECK IGNITION COIL WITH POWER TRANSISTOR

Refer to “Component Inspection”, EC-QG-331331. OK or NG OK

©

GO TO 18.

NG

©

Replace ignition coil with power transistor.

EC-330

QG16I18DE

IGNITION SIGNAL

Diagnostic Procedure (Cont’d)

18

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0547

IGNITION COIL WITH POWER TRANSISTOR 1. 2.

NCEC0547S01

Disconnect ignition coil with power transistor harness connector. Check ignition coil with power transistor for resistance as show in the figure. Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) - 2 (−)

Except 0 or ∞

SEF371Q

1 (+) - 3 (−) Except 0 1 (+) - 2 (−)

If NG, replace ignition coil with power transistor assembly.

CONDENSER 1. 2.

NCEC0547S02

Disconnect condenser harness connector. Check condenser continuity between terminals 1 and 2. Resistance: Above 1 MΩ at 25°C (77°F)

SEF059X

EC-331

QG16I18DE

START SIGNAL CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0441

Specification data are reference values. MONITOR ITEM START SIGNAL

CONDITION

SPECIFICATION

I Ignition switch: ON , START , ON

OFF , ON , OFF

ECM Terminals and Reference Value

NCEC0442

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 41

WIRE COLOR

B/Y

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”]

Approximately 0V

[Ignition switch “START”]

9 - 12V

Start signal

EC-332

START SIGNAL

QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0440

BATTERY

Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC

OFF

ST

IGNITION SWITCH

ACC ON

FUSE BLOCK (J/B)

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

EC-333

YEC282

START SIGNAL

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

=NCEC0443

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

©

GO TO 2.

No

©

GO TO 3.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Turn ignition switch “ON”. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

PEF111P

Condition

“START SIGNAL”

IGN “ON”

OFF

IGN “START”

ON OK or NG

OK

©

INSPECTION END

NG

©

GO TO 4.

EC-334

MTBL0140

START SIGNAL

QG16I18DE Diagnostic Procedure (Cont’d)

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Turn ignition switch to “START”. 2. Check voltage between ECM terminal 41 and ground under the following conditions.

SEF142X

Condition

Voltage

Ignition switch “START” Except above

Battery voltage Approximately 0V MTBL0143

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 I 10A fuse I Harness for open or short between ECM and ignition switch OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

EC-335

QG16I18DE

FUEL PUMP System Description

System Description Sensor

Input Signal to ECM

Camshaft position sensor (PHASE)

Engine speed

Ignition switch

Start signal

NCEC0444

ECM function Fuel pump control

Actuator

Fuel pump relay

The ECM activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the ECM receives a 180° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to perform. If the 180° signal is not received when the ignition switch is on, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition

Fuel pump operation

Ignition switch is turned to ON.

Operates for 1 second

Engine running and cranking

Operates

When engine is stopped (Signal is not sent from camshaft position sensor.)

Stops in 1.5 seconds

Except as shown above

Stops

Component Description

NCEC0501

A turbine type design fuel pump is used in the fuel tank.

AEC801

CONSULT-II Reference Value in Data Monitor Mode

NCEC0445

MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

I Ignition switch is turned to ON (Operates for 1 second) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds)

ON

I Except as shown above

OFF

EC-336

QG16I18DE

FUEL PUMP

ECM Terminals and Reference Value

ECM Terminals and Reference Value

NCEC0446

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

21

WIRE COLOR

B/P

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] I For 1 second after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

Fuel pump relay

EC-337

FUEL PUMP

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0447

YEC280

EC-338

QG16I18DE

FUEL PUMP

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0448

CHECK OVERALL FUNCTION

1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with fingers.

SEF143X

Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned “ON”. OK or NG OK

©

INSPECTION END

NG

©

GO TO 2.

2

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay.

SEF071X

3. Turn ignition switch “ON”. 4. Check voltage between terminals 1, 3 and ground with CONSULT-II or tester.

SEF144X

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-339

FUEL PUMP

QG16I18DE

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. I 15A fuse I Harness for open or short between fuse and fuel pump relay ©

4

Repair harness or connectors.

CHECK POWER GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector.

SEF299W

3. Check harness continuity between fuel pump harness connector terminal 2 and body ground, terminal 1 and fuel pump relay connector terminal 9J. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between fuel pump and body ground I Harness for open or short between fuel pump and fuel pump relay ©

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 21 and fuel pump relay connector terminal 19C. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 I Harness for open or short between ECM and fuel pump relay

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-340

QG16I18DE

FUEL PUMP

Diagnostic Procedure (Cont’d)

8

CHECK FUEL PUMP RELAY

Refer to “Component Inspection”, EC-QG-341. OK or NG OK

©

GO TO 9.

NG

©

Replace fuel pump relay.

9

CHECK FUEL PUMP

Refer to “Component Inspection”, EC-QG-341. OK or NG OK

©

GO TO 10.

NG

©

Replace fuel pump.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0449

FUEL PUMP RELAY

NCEC0449S01

Check continuity between terminals 3 and 5. Conditions

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

If NG, replace relay. SEF145X

FUEL PUMP 1. 2.

Disconnect fuel pump harness connector. Check resistance between terminals 1 and 2. Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] If NG, replace fuel pump.

SEF326W

EC-341

NCEC0449S02

QG16I18DE

POWER STEERING OIL PRESSURE SWITCH Component Description

Component Description

Power steering oil pressure switch

NCEC0451

The power steering oil pressure switch is attached to the power steering high-pressure tube and detects a power steering load. When a power steering load is detected, it signals the ECM. The ECM adjusts the IACV-AAC valve to increase the idle speed and adjust for the increased load.

NEF124A

CONSULT-II Reference Value in Data Monitor Mode

NCEC0452

Specification data are reference values. MONITOR ITEM

PW/ST SIGNAL

CONDITION I Engine: After warming up, idle the engine

SPECIFICATION

Steering wheel in neutral position (forward direction)

OFF

The steering wheel is fully turned

ON

ECM Terminals and Reference Value

NCEC0453

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

46

WIRE COLOR

PU/W

ITEM

CONDITION

[Engine is Power steering oil pressure I Steering switch [Engine is I Steering

DATA (DC Voltage)

running] wheel is fully turned

Approximately 0V

running] wheel is not turned

Approximately 5V

EC-342

POWER STEERING OIL PRESSURE SWITCH

QG16I18DE Wiring Diagram

Wiring Diagram

NCEC0450

YEC254

EC-343

POWER STEERING OIL PRESSURE SWITCH

QG16I18DE

Diagnostic Procedure

Diagnostic Procedure 1

=NCEC0454

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

©

GO TO 2.

No

©

GO TO 3.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Check “PW/ST SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

PEF591I

Steering is in neutral position

OFF

Steering is turned

ON MTBL0141

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

EC-344

POWER STEERING OIL PRESSURE SWITCH

QG16I18DE

Diagnostic Procedure (Cont’d)

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 46 and ground under the following conditions.

SEF148X

Condition

Voltage

When steering wheel is turned quickly

Approximately 0V

Except above

Approximately 5V MTBL0142

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

4

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect power steering oil pressure switch harness connector. 3. Check harness continuity between power steering oil pressure switch harness terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and power steering oil pressure switch harness terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 7.

NG

©

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F4, E42 I Harness for open or short between ECM and power steering oil pressure switch

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-345

POWER STEERING OIL PRESSURE SWITCH

QG16I18DE

Diagnostic Procedure (Cont’d)

7

CHECK POWER STEERING OIL PRESSURE SWITCH

Refer to “Component Inspection”, EC-QG-346. OK or NG OK

©

GO TO 8.

NG

©

Replace power steering oil pressure switch.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102.

©

INSPECTION END

Component Inspection

NCEC0455

POWER STEERING OIL PRESSURE SWITCH 1. 2.

NCEC0455S01

Disconnect power steering oil pressure switch harness connector then start engine. Check continuity between terminals 1 and 2. Refer to wiring diagram. Conditions

Continuity

Steering wheel is being turned.

Yes

Steering wheel is not being turned.

No

If NG, replace power steering oil pressure switch.

EC-346

QG16I18DE

REFRIGERANT PRESSURE SENSOR

Description

Description

NLEC0580

The refrigerant pressure sensor is installed at the liquid tank of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system.

JEF147Y

SEF099X

ECM Terminals and Reference Value

NLEC0581

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

58

B

Sensor’s ground

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

74

R/L

Refrigerant pressure sensor

[Engine is running] I Warm-up condition I Both A/C switch and blower switch are “ON” (Compressor operates.)

1.0 - 4.0V

111

G

Sensor’s power supply

[Ignition switch “ON”]

Approximately 5V

EC-347

REFRIGERANT PRESSURE SENSOR

QG16I18DE

Wiring Diagram

Wiring Diagram REFRIGERANT SENSOR

: Detectable line for DTC : Non-detectable line for DTC

ECM

EC-348

YEC790

QG16I18DE

REFRIGERANT PRESSURE SENSOR

Diagnostic Procedure

Diagnostic Procedure 1

NLEC0590

CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION

1. Start engine and warm it up to normal operating temperature. 2. Turn A/C switch and blower switch “ON”. 3. Check voltage between ECM terminal 74 and ground with CONSULT-II or tester.

SEF952XA

OK or NG OK

©

INSPECTION END

NG

©

GO TO 2.

2

CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Turn A/C switch and blower switch “OFF”. 2. Stop engine. 3. Disconnect refrigerant pressure sensor harness connector.

JEF147Y

4. Turn ignition switch “ON”. 5. Check voltage between refrigerant pressure sensor terminal 1 and ground with CONSULT-II or tester.

NEF243A

OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-349

REFRIGERANT PRESSURE SENSOR

QG16I18DE

Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM and refrigerant pressure sensor ©

4

Repair harness or connectors.

CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between refrigerant pressure sensor terminal 3 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM and refrigerant pressure sensor ©

6

Repair open circuit or short to power in harness or connectors.

CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 74 and refrigerant pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM and refrigerant pressure sensor ©

8

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK REFRIGERANT PRESSURE SENSOR

Refer to HA section, “Refrigerant pressure sensor”. OK or NG OK

©

GO TO 9.

NG

©

Replace refrigerant pressure sensor.

9

CHECK INTERMITTENT INCIDENT

Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-QG-102. ©

INSPECTION END

EC-350

QG16I18DE

ELECTRICAL LOAD SIGNAL

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0548

Specification data are reference values. MONITOR ITEM

CONDITION

I Ignition switch: ON

LOAD SIGNAL

HEATER FAN SW

I Ignition switch: ON

SPECIFICATION

Rear window defogger is operating ON and/or lighting switch is on. Rear window defogger is not operOFF ating and lighting switch is not on. Blower fan motor is operating

ON

Blower fan motor is not operating

OFF

ECM Terminals and Reference Value

NCEC0549

Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

50

51

R

LG/B

ITEM

Electric load signal (Load switch)

Blower fan motor switch

CONDITION

DATA (DC Voltage)

[Engine is running] I Rear window defogger is operating and/or lighting switch is on

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Rear window defogger is not operating and lighting switch is not on

Approximately 0V

[Engine is running] I Blower fan motor is operating

Approximately 0V

[Engine is running] I Blower fan motor is not operating

Approximately 5V

EC-351

ELECTRICAL LOAD SIGNAL

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0550

YEC255

EC-352

ELECTRICAL LOAD SIGNAL

QG16I18DE Wiring Diagram (Cont’d)

YEC077A

EC-353

MI & DATA LINK CONNECTORS

QG16I18DE

Wiring Diagram

Wiring Diagram

NCEC0466

YEC078A

EC-354

SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure Regulator

Fuel Pressure Regulator Fuel pressure at idling kPa (bar, kg/cm2, psi)

NCEC0467

Vacuum hose is connected

Approximately 235 (2.35, 2.4, 34)

Vacuum hose is disconnected

Approximately 294 (2.94, 3.0, 43)

Idle Speed and Ignition Timing Target idle speed* Air conditioner: ON

rpm

NCEC0468

700±50

rpm

825 or more

Ignition timing

8°±5° BTDC

Throttle position sensor idle position

V

0.35 - 0.65

*: Under the following conditions: I Air conditioner switch: OFF I Electrical load: OFF (Lights, heater fan & rear window defogger) I Steering wheel: Kept in straight-ahead position

Mass Air Flow Sensor

NCEC0470

Supply voltage (Heater)

V

Battery voltage (11 - 14)

Supply voltage (Sensor)

V

Approximately 5

Output voltage

V

1.0 - 1.7*

Mass air flow (Using CONSULT-II or GST)

1.0 - 4.0 at idle* 5.0 - 10.0 at 2,500 rpm*

g⋅m/sec

*: Engine is warmed up to normal operating temperature and idling under no-load.

Intake Air Temperature Sensor Temperature

°C (°F)

Resistance

NCEC0480

kΩ

20 (68)

2.1 - 2.9

80 (176)

0.27 - 0.38

Engine Coolant Temperature Sensor Temperature

°C (°F)

Resistance

kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

Throttle Position Sensor Throttle valve conditions

NCEC0471

NCEC0477

Resistance [at 25°C (77°F)]

Completely closed

Approximately 0.6 kΩ (a)

Partially open

Between (a) and (b)

Completely open

Approximately 4.0 kΩ (b)

Heated Oxygen Sensor 1 Heater (Front) Resistance [at 25°C (77°F)] Ω

NCEC0478

2.3 - 4.3

Heated Oxygen Sensor 2 Heater (Rear) Resistance [at 25°C (77°F)] Ω

2.3 - 4.3

EC-355

NCEC0483

SERVICE DATA AND SPECIFICATIONS (SDS) Crankshaft Position Sensor (POS)

Crankshaft Position Sensor (POS)

NCEC0558

Resistance Ω [at 25°C (77°F)]

Terminal No. (Polarity) 3 (+) - 1 (−)

Except 0 or ∞

2 (+) - 1 (−) 3 (+) - 2 (−)

Camshaft Position Sensor (PHASE)

NCEC0559

Resistance Ω [at 25°C (77°F)]

Terminal No. (Polarity) 3 (+) - 1 (−)

Except 0 or ∞

2 (+) - 1 (−) 3 (+) - 2 (−)

EGR Volume Control Valve (If so equipped)

NCEC0560

Resistance Ω [at 20°C (68°F)]

Terminal No. 1-2 2-3

20 - 24 4-5 5-6

EGR Temperature Sensor (If so equipped) EGR temperature °C (°F)

Voltage V

Resistance MΩ

0 (32)

4.56

0.62 - 1.05

50 (122)

2.25

0.065 - 0.094

100 (212)

0.59

0.011 - 0.015

EVAP Canister Purge Volume Control Valve Resistance [at 20°C (68°F)] Ω

NCEC0472

NCEC0481

31 - 35

IACV-AAC Valve

NCEC0474

Resistance Ω [at 20°C (68°F)]

Terminal No. 1-2 2-3

20 - 24 4-5 5-6

Injector Resistance [at 25°C (77°F)] Ω

NCEC0475

13.5 - 17.5

EC-356

SERVICE DATA AND SPECIFICATIONS (SDS) Ignition Coil with Power Transistor

Ignition Coil with Power Transistor Terminal No. (Polarity)

Resistance Ω [at 25°C (77°F)]

3 (+) - 2 (−)

Except 0 or ∞

NCEC0561

1 (+) - 3 (−) Except 0 1 (+) - 2 (−)

Fuel Pump Resistance [at 25°C (77°F)] Ω

NCEC0473

0.2 - 5.0

EC-357

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

EC-358

ENGINE CONTROL SYSTEM SECTION

EC EC

CONTENTS SR20DE TROUBLE DIAGNOSIS - INDEX ....................................6 Alphabetical & P No. Index for DTC ...........................6 PRECAUTIONS .............................................................10 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............10 Precautions for On Board Diagnostic (OBD) System of Engine and CVT.......................................10 Engine Fuel & Emission Control System ..................11 Precautions ................................................................12 Wiring Diagrams and Trouble Diagnosis...................13 PREPARATION .............................................................14 Special Service Tools ................................................14 Commercial Service Tool...........................................14 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................15 Engine Control Component Parts Location...............15 Circuit Diagram ..........................................................19 System Diagram ........................................................20 Vacuum Hose Drawing ..............................................21 System Chart .............................................................22 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................23 Multiport Fuel Injection (MFI) System .......................23 Distributor Ignition (DI) System .................................25 Air Conditioning Cut Control......................................26 Fuel Cut Control (at no load & high engine speed) ........................................................................27 Evaporative Emission System ...................................27 Positive Crankcase Ventilation ..................................30 BASIC SERVICE PROCEDURE ...................................31 Fuel Pressure Release ..............................................31 Fuel Pressure Check .................................................31 Fuel Pressure Regulator Check ................................32 Injector .......................................................................32 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................34

Idle Air Volume Learning ...........................................46 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................48 Introduction ................................................................48 Two Trip Detection Logic ...........................................48 Emission-related Diagnostic Information ...................49 Malfunction Indicator (MI) ..........................................58 OBD System Operation Chart ...................................63 CONSULT-II ...............................................................68 Generic Scan Tool (GST) ..........................................78 TROUBLE DIAGNOSIS - INTRODUCTION..................80 Introduction ................................................................80 Work Flow..................................................................82 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........84 Basic Inspection.........................................................84 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................92 DTC Inspection Priority Chart....................................92 Fail-safe Chart ...........................................................93 Symptom Matrix Chart...............................................94 CONSULT-II Reference Value in Data Monitor Mode ..........................................................................98 Major Sensor Reference Graph in Data Monitor Mode ........................................................................100 ECM Terminals and Reference Value .....................103 TROUBLE DIAGNOSIS - SPECIFICATION VALUE ..110 Description ...............................................................110 Testing Condition .....................................................110 Inspection Procedure...............................................110 Diagnostic Procedure .............................................. 111 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................114 Description ...............................................................114 Diagnostic Procedure ..............................................114 TROUBLE DIAGNOSIS FOR POWER SUPPLY........115 Main Power Supply and Ground Circuit..................115

CONTENTS DTC P0100 MASS AIR FLOW SENSOR (MAFS)......120 Component Description ...........................................120 CONSULT-II Reference Value in Data Monitor Mode ........................................................................120 ECM Terminals and Reference Value .....................120 On Board Diagnosis Logic.......................................120 DTC Confirmation Procedure ..................................121 Wiring Diagram ........................................................122 Diagnostic Procedure ..............................................123 Component Inspection.............................................126 DTC P0110 INTAKE AIR TEMPERATURE SENSOR ......................................................................127 Component Description ...........................................127 On Board Diagnosis Logic.......................................127 DTC Confirmation Procedure ..................................127 Wiring Diagram ........................................................128 Diagnostic Procedure ..............................................129 Component Inspection.............................................131 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT) .......................................132 Component Description ...........................................132 CONSULT-II Reference Value in Data Monitor Mode ........................................................................132 On Board Diagnosis Logic.......................................132 DTC Confirmation Procedure ..................................133 Wiring Diagram ........................................................134 Diagnostic Procedure ..............................................135 Component Inspection.............................................136 DTC P0120 THROTTLE POSITION SENSOR ...........137 Component Description ...........................................137 CONSULT-II Reference Value in Data Monitor Mode ........................................................................137 ECM Terminals and Reference Value .....................138 On Board Diagnosis Logic.......................................138 DTC Confirmation Procedure ..................................138 Wiring Diagram ........................................................140 Diagnostic Procedure ..............................................141 Component Inspection.............................................142 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT).....................................................144 Component Description ...........................................144 CONSULT-II Reference Value in Data Monitor Mode ........................................................................144 ECM Terminals and Reference Value .....................144 On Board Diagnosis Logic.......................................145 DTC Confirmation Procedure ..................................145 Overall Function Check ...........................................146 Wiring Diagram ........................................................147 Diagnostic Procedure ..............................................148 Component Inspection.............................................149

(Cont’d)

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING) .....................150 Component Description ...........................................150 CONSULT-II Reference Value in Data Monitor Mode ........................................................................150 ECM Terminals and Reference Value .....................150 On Board Diagnosis Logic.......................................151 DTC Confirmation Procedure ..................................151 Overall Function Check ...........................................152 Diagnostic Procedure ..............................................153 Component Inspection.............................................154 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING) ......................156 Component Description ...........................................156 CONSULT-II Reference Value in Data Monitor Mode ........................................................................156 ECM Terminals and Reference Value .....................156 On Board Diagnosis Logic.......................................157 DTC Confirmation Procedure ..................................157 Overall Function Check ...........................................158 Diagnostic Procedure ..............................................159 Component Inspection.............................................160 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING).......................162 Component Description ...........................................162 CONSULT-II Reference Value in Data Monitor Mode ........................................................................162 ECM Terminals and Reference Value .....................162 On Board Diagnosis Logic.......................................163 DTC Confirmation Procedure ..................................163 Overall Function Check ...........................................164 Wiring Diagram ........................................................165 Diagnostic Procedure ..............................................166 Component Inspection.............................................169 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)........................................170 Component Description ...........................................170 CONSULT-II Reference Value in Data Monitor Mode ........................................................................170 ECM Terminals and Reference Value .....................170 On Board Diagnosis Logic.......................................171 DTC Confirmation Procedure ..................................171 Wiring Diagram ........................................................172 Diagnostic Procedure ..............................................173 Component Inspection.............................................174 DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER.......................................................175 Description ...............................................................175 CONSULT-II Reference Value in Data Monitor Mode ........................................................................175 ECM Terminals and Reference Value .....................175 On Board Diagnosis Logic.......................................175

EC-2

CONTENTS DTC Confirmation Procedure ..................................175 Wiring Diagram ........................................................177 Diagnostic Procedure ..............................................178 Component Inspection.............................................179 DTC P0137 HEATED OXYGEN SENSOR 2(REAR) (MIN. VOLTAGE MONITORING).................................180 Component Description ...........................................180 CONSULT-II Reference Value in Data Monitor Mode ........................................................................180 ECM Terminals and Reference Value .....................180 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................181 Overall Function Check ...........................................182 Wiring Diagram ........................................................183 Diagnostic Procedure ..............................................184 Component Inspection.............................................186 DTC P0138 HEATED OXYGEN SENSOR 2(REAR) (MAX. VOLTAGE MONITORING) ...............................187 Component Description ...........................................187 CONSULT-II Reference Value in Data Monitor Mode ........................................................................187 ECM Terminals and Reference Value .....................187 On Board Diagnosis Logic.......................................187 DTC Confirmation Procedure ..................................188 Overall Function Check ...........................................189 Wiring Diagram ........................................................190 Diagnostic Procedure ..............................................191 Component Inspection.............................................193 DTC P0139 HEATED OXYGEN SENSOR 2(REAR) (RESPONSE MONITORING).......................................194 Component Description ...........................................194 CONSULT-II Reference Value in Data Monitor Mode ........................................................................194 ECM Terminals and Reference Value .....................194 On Board Diagnosis Logic.......................................194 DTC Confirmation Procedure ..................................195 Overall Function Check ...........................................196 Wiring Diagram ........................................................197 Diagnostic Procedure ..............................................198 Component Inspection.............................................200 DTC P0140 HEATED OXYGEN SENSOR 2(REAR) (HIGH VOLTAGE)........................................................201 Component Description ...........................................201 CONSULT-II Reference Value in Data Monitor Mode ........................................................................201 ECM Terminals and Reference Value .....................201 On Board Diagnosis Logic.......................................201 DTC Confirmation Procedure ..................................202 Overall Function Check ...........................................202 Wiring Diagram ........................................................203 Diagnostic Procedure ..............................................204 Component Inspection.............................................205

(Cont’d)

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER .........................................................207 Description ...............................................................207 CONSULT-II Reference Value in Data Monitor Mode ........................................................................207 ECM Terminals and Reference Value .....................207 On Board Diagnosis Logic.......................................207 DTC Confirmation Procedure ..................................208 Wiring Diagram ........................................................209 Diagnostic Procedure ..............................................210 Component Inspection.............................................211 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE) ............................................212 On Board Diagnosis Logic.......................................212 DTC Confirmation Procedure ..................................212 Wiring Diagram ........................................................213 Diagnostic Procedure ..............................................214 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE) .............................................218 On Board Diagnosis Logic.......................................218 DTC Confirmation Procedure ..................................218 Wiring Diagram ........................................................220 Diagnostic Procedure ..............................................221 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE ...............224 On Board Diagnosis Logic.......................................224 DTC Confirmation Procedure ..................................224 Diagnostic Procedure ..............................................225 Component Inspection.............................................229 DTC P0325 KNOCK SENSOR (KS) ...........................230 Component Description ...........................................230 ECM Terminals and Reference Value .....................230 On Board Diagnosis Logic.......................................230 DTC Confirmation Procedure ..................................230 Wiring Diagram ........................................................231 Diagnostic Procedure ..............................................232 Component Inspection.............................................233 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)..............................................................234 Component Description ...........................................234 ECM Terminals and Reference Value .....................234 On Board Diagnosis Logic.......................................234 DTC Confirmation Procedure ..................................235 Wiring Diagram ........................................................236 Diagnostic Procedure ..............................................237 Component Inspection.............................................238 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).........................................................................239 Component Description ...........................................239 ECM Terminals and Reference Value .....................239 On Board Diagnosis Logic.......................................240 DTC Confirmation Procedure ..................................240

EC-3

CONTENTS Wiring Diagram ........................................................242 Diagnostic Procedure ..............................................243 Component Inspection.............................................245 DTC P0420 THREE WAY CATALYST FUNCTION ...246 On Board Diagnosis Logic.......................................246 DTC Confirmation Procedure ..................................246 Overall Function Check ...........................................247 Diagnostic Procedure ..............................................247 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................250 Description ...............................................................250 CONSULT-II Reference Value in Data Monitor Mode ........................................................................250 ECM Terminals and Reference Value .....................251 On Board Diagnosis Logic.......................................251 DTC Confirmation Procedure ..................................251 Wiring Diagram ........................................................252 Diagnostic Procedure ..............................................253 Component Inspection.............................................254 DTC P0500 VEHICLE SPEED SENSOR (VSS) .........255 Component Description ...........................................255 ECM Terminals and Reference Value .....................255 On Board Diagnosis Logic.......................................255 DTC Confirmation Procedure ..................................255 Wiring Diagram ........................................................257 Diagnostic Procedure ..............................................260 DTC P0505 IDLE AIR CONTROL VALVE (IACV) AUXILIARY AIR CONTROL (AAC) VALVE ...............263 Description ...............................................................263 CONSULT-II Reference Value in Data Monitor Mode ........................................................................264 ECM Terminals and Reference Value .....................264 On Board Diagnosis Logic.......................................264 DTC Confirmation Procedure ..................................264 Wiring Diagram ........................................................265 Diagnostic Procedure ..............................................266 Component Inspection.............................................270 DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED) ......................................271 Component Description ...........................................271 CONSULT-II Reference Value in Data Monitor Mode ........................................................................271 ECM Terminals and Reference Value .....................271 On Board Diagnosis Logic.......................................271 DTC Confirmation Procedure ..................................272 Overall Function Check ...........................................272 Wiring Diagram ........................................................273 Diagnostic Procedure ..............................................274 Component Inspection.............................................276 DTC P0605 ECM .........................................................277 Component Description ...........................................277 On Board Diagnosis Logic.......................................277

(Cont’d)

DTC Confirmation Procedure ..................................277 Diagnostic Procedure ..............................................278 DTC P1217 OVERHEAT (COOLING SYSTEM) .........279 System Description..................................................279 CONSULT-II Reference Value in Data Monitor Mode ........................................................................280 ECM Terminals and Reference Value .....................280 On Board Diagnosis Logic.......................................280 Overall Function Check ...........................................281 Wiring Diagram ........................................................282 Diagnostic Procedure ..............................................284 Main 12 Causes of Overheating..............................288 Component Inspection.............................................289 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)..................................................290 Component Description ...........................................290 ECM Terminals and Reference Value .....................290 On Board Diagnosis Logic.......................................290 DTC Confirmation Procedure ..................................291 Wiring Diagram ........................................................292 Diagnostic Procedure ..............................................293 Component Inspection.............................................294 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE .............................................................................295 System Description..................................................295 ECM Terminals and Reference Value .....................295 On Board Diagnosis Logic.......................................295 DTC Confirmation Procedure ..................................295 Wiring Diagram ........................................................296 Diagnostic Procedure ..............................................297 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH .......................................................................298 Component Description ...........................................298 CONSULT-II Reference Value in Data Monitor Mode ........................................................................298 ECM Terminals and Reference Value .....................298 On Board Diagnosis Logic.......................................298 DTC Confirmation Procedure ..................................298 Overall Function Check ...........................................299 Wiring Diagram ........................................................300 Diagnostic Procedure ..............................................301 INJECTOR ...................................................................302 Component Description ...........................................302 CONSULT-II Reference Value in Data Monitor Mode ........................................................................302 ECM Terminals and Reference Value .....................302 Wiring Diagram ........................................................303 Diagnostic Procedure ..............................................304 Component Inspection.............................................305 IGNITION SIGNAL.......................................................306 Component Description ...........................................306

EC-4

CONTENTS CONSULT-II Reference Value in Data Monitor Mode ........................................................................306 ECM Terminals and Reference Value .....................306 Wiring Diagram ........................................................308 Diagnostic Procedure ..............................................309 Component Inspection.............................................310 START SIGNAL...........................................................312 CONSULT-II Reference Value in Data Monitor Mode ........................................................................312 ECM Terminals and Reference Value .....................312 Wiring Diagram ........................................................313 Diagnostic Procedure ..............................................314 FUEL PUMP.................................................................316 System Description..................................................316 Component Description ...........................................316 CONSULT-II Reference Value in Data Monitor Mode ........................................................................316 ECM Terminals and Reference Value .....................316 Wiring Diagram ........................................................317 Diagnostic Procedure ..............................................318 Component Inspection.............................................320 POWER STEERING OIL PRESSURE SWITCH.........321 Component Description ...........................................321 CONSULT-II Reference Value in Data Monitor Mode ........................................................................321 ECM Terminals and Reference Value .....................321 Wiring Diagram ........................................................322

(Cont’d)

Diagnostic Procedure ..............................................323 Component Inspection.............................................324 ELECTRICAL LOAD SIGNAL.....................................325 CONSULT-II Reference Value in Data Monitor Mode ........................................................................325 ECM Terminals and Reference Value .....................325 Wiring Diagram ........................................................326 MI & DATA LINK CONNECTORS ..............................329 Wiring Diagram ........................................................329

SERVICE DATA AND SPECIFICATIONS (SDS) .......330 Fuel Pressure Regulator..........................................330 Idle Speed and Ignition Timing................................330 Ignition Coil ..............................................................330 Mass Air Flow Sensor..............................................330 Engine Coolant Temperature Sensor ......................330 Fuel Pump ...............................................................330 IACV-AAC Valve ......................................................330 Injector .....................................................................330 Throttle Position Sensor ..........................................331 Heated Oxygen Sensor 1 (Front) Heater ................331 Intake Air Temperature Sensor................................331 EVAP Canister Purge Volume Control Valve ..........331 Heated Oxygen Sensor 1 (Rear) Heater.................331 Crankshaft Position Sensor (OBD)..........................331

EC-5

SR20DE

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NCEC0001

ALPHABETICAL INDEX FOR DTC

NCEC0001S01

DTC*6 Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

—

—

EC-SR-93

AIR TEMP SEN/CIRC *7

P0110

0110

EC-SR-127

A/T DIAG COMM LINE *7

P1605

1605

EC-SR-295

ATF TEMP SEN/CIRC *7

P0710

0710

Refer to AT section.

CAM POS SEN/CIRC

P0340

0340

EC-SR-239

CLOSED TP SW/CIRC *7

P0510

0510

EC-SR-271

COOLANT T SEN/CIRC

P0115

0115

EC-SR-132

CPS/CIRC (OBD) COG *7

P1336

1336

EC-SR-290

CPS/CIRCUIT (OBD) *7

P0335

0335

EC-SR-234

CYL 1 MISFIRE *7

P0301

0301

EC-SR-224

CYL 2 MISFIRE *7

P0302

0302

EC-SR-224

CYL 3 MISFIRE *7

P0303

0303

EC-SR-224

CYL 4 MISFIRE *7

P0304

0304

EC-SR-224

ECM *7

P0605

0605

EC-SR-277

ENGINE SPEED SIG *7

P0725

0725

Refer to AT section.

LINE PRESS SE *7

P1791

1791

Refer to AT section.

HO2S1 HTR (B1)

P0135

0135

EC-SR-175

HO2S1 (B1)

P0130

0130

EC-SR-144

HO2S1 (B1) *7

P0131

0131

EC-SR-150

HO2S1 (B1) *7

P0132

0132

EC-SR-156

HO2S1 (B1) *7

P0133

0133

EC-SR-162

HO2S1 (B1) *7

P0134

0134

EC-SR-170

FUEL SYS -LEAN/BK1 *7

P0171

0171

EC-SR-212

FUEL SYS -RICH/BK1 *7

P0172

0172

EC-SR-218

IACV/AAC VLV/CIRC *7

P0505

0505

EC-SR-263

IN PY SPD SEN/CIRC *7

P0715

0715

Refer to AT section.

KNOCK SEN/CIRC -B1

P0325

0325

EC-SR-230

L/PRESS SOL/CIRC *7

P0745

0745

Refer to AT section.

MAF SEN/CIRCUIT *3

P0100

0100

EC-SR-120

MULTI CYL MISFIRE *7

P0300

0300

EC-SR-224

P1610 - P1615

1610 - 1615

Refer to EL section.

NO SELF DIAGNOSTIC FAILURE INDICATED

P0000

0000

—

NO SELF DIAGNOSTIC FAILURE INDICATED

No DTC

Flashing*5

EC-SR-59

ENG OVER TEMP

P1217

1217

EC-SR-279

P-N POS SW/CIRCUIT *7

P1706

1706

EC-SR-298

Unable to access ECM

NATS MALFUNCTION

EC-6

TROUBLE DIAGNOSIS — INDEX

SR20DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*6 Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

PNP SW/CIRC *7

P0705

0705

Refer to AT section.

PURG VOLUME CONT/V *7

P0443

0443

EC-SR-250

HO2S2 (B1) *7

P0137

0137

EC-SR-180

HO2S2 (B1) *7

P0138

0138

EC-SR-187

HO2S2 (B1) *7

P0139

0139

EC-SR-194

HO2S2 (B1) *7

P0140

0140

EC-SR-201

HO2S2 HTR (B1) *7

P0141

0141

EC-SR-207

STEP MOTOR CIRC -B1 *7

P1777

1777

Refer to AT section.

STEP MOTOR FNC *7

P1778

1778

Refer to AT section.

TCC SOLENOID/CIRC *7

P0740

0740

Refer to AT section.

THRTL POS SEN/CIRC *3

P0120

0120

EC-SR-137

TP SEN/CIRC A/T *7

P1705

1705

Refer to AT section.

TW CATALYST SYSTEM *7

P0420

0420

EC-SR-246

VEH SPD SEN/CIR AT *4 *7

P0720

0720

Refer to AT section.

VEH SPEED SEN/CIRC *4

P0500

0500

EC-SR-255

*1: *2: *3: *4:

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. When the fail-safe operation occurs, the MI illuminates. The MI illuminates when the “Secondary speed sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. *5: While engine is running. *6: 1st trip DTC No. is the same as DTC No. *7: Not available for “Eastern Europe models”.

P NO. INDEX FOR DTC

NCEC0001S02

DTC*6 CONSULT-II GST*2

ECM*1

—

—

No DTC

Items (CONSULT-II screen terms)

Reference page

Unable to access ECM

EC-SR-93

Flashing*5

NO SELF DIAGNOSTIC FAILURE INDICATED

EC-SR-59

P0000

0000

NO SELF DIAGNOSTIC FAILURE INDICATED

—

P0100

0100

MAF SEN/CIRCUIT*3

EC-SR-120

P0110

0110

AIR TEMP SEN/CIRC *7

EC-SR-127

P0115

0115

COOLANT T SEN/CIRC *3

EC-SR-132

P0120

0120

THRTL POS SEN/CIRC *3

EC-SR-137

P0130

0130

HO2S1 (B1)

EC-SR-144

P0131

0131

HO2S1 (B1) *7

EC-SR-150

P0132

0132

HO2S1 (B1) *7

EC-SR-156

P0133

0133

HO2S1 (B1) *7

EC-SR-162

P0134

0134

HO2S1 (B1) *7

EC-SR-170

P0135

0135

HO2S1 HTR (B1) *7

EC-SR-175

EC-7

TROUBLE DIAGNOSIS — INDEX

SR20DE

Alphabetical & P No. Index for DTC (Cont’d) DTC*6 Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

P0137

0137

HO2S2 (B1) *7

EC-SR-180

P0138

0138

HO2S2 (B1) *7

EC-SR-187

P0139

0139

HO2S2 (B1) *7

EC-SR-194

P0140

0140

HO2S2 (B1) *7

EC-SR-201

P0141

0141

HO2S2 HTR (B1) *7

EC-SR-207

P0171

0171

FUEL SYS -LEAN/BK1 *7

EC-SR-212

P0172

0172

FUEL SYS -RICH/BK1 *7

EC-SR-218

P0300

0300

MULTI CYL MISFIRE *7

EC-SR-224

P0301

0301

CYL 1 MISFIRE *7

EC-SR-224

P0302

0302

CYL 2 MISFIRE *7

EC-SR-224

P0303

0303

CYL 3 MISFIRE *7

EC-SR-224

P0304

0304

CYL 4 MISFIRE *7

EC-SR-224

P0325

0325

KNOCK SEN/CIRC -B1

EC-SR-230

P0335

0335

CPS/CIRCUIT (POS) *7

EC-SR-234

P0340

0340

CAM POS SEN/CIRC

EC-SR-239

P0420

0420

TW CATALYST SYS -B1 *7

EC-SR-246

P0443

0443

PURG VOLUME CONT/V *7

EC-SR-250

P0500

0500

VEH SPEED SEN/CIRC *4

EC-SR-255

P0505

0505

IACV/AAC VLV/CIRC *7

EC-SR-263

P0510

0510

CLOSED TP SW/CIRC *7

EC-SR-271

P0605

0605

ECM *7

EC-SR-277

P0705

0705

PNP SW/CIRC *7

Refer to AT section.

P0710

0710

ATF TEMP SEN/CIRC *7

Refer to AT section.

P0715

0715

IN PY SPD SEN/CIRC *7

Refer to AT section.

P0720

0720

VEH SPD SEN/CIR AT *4 *7

Refer to AT section.

P0725

0725

ENGINE SPEED SIG *7

Refer to AT section.

P0740

0740

TCC SOLENOID/CIRC *7

Refer to AT section.

P0745

0745

L/PRESS SOL/CIRC *7

Refer to AT section.

P1217

1217

ENG OVER TEMP

EC-SR-279

P1336

1336

CPS/CIRC (OBD) COG *7

EC-SR-290

EC-8

TROUBLE DIAGNOSIS — INDEX

SR20DE

Alphabetical & P No. Index for DTC (Cont’d) P1605

1605

P1610 - 1615

1610 - 1615

P1705

A/T DIAG COMM LINE *7

EC-SR-295

NATS MALFUNCTION

Refer to EL section.

1705

TP SEN/CIRC A/T *7

Refer to AT section.

P1706

1706

P-N POS SW/CIRCUIT *7

P1777

1777

STEP MOTOR CIRC *7

Refer to AT section.

P1778

1778

STEP MOTOR FNC *7

Refer to AT section.

P1791

1791

LINE PRESS SE *7

Refer to AT section.

*1: *2: *3: *4:

EC-SR-298

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. When the fail-safe operation occurs, the MI illuminates. The MI illuminates when the “Secondary speed sensor signal” and the “Vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal” meet the fail-safe condition at the same time. *5: While engine is running. *6: 1st trip DTC No. is the same as DTC No. *7: Not available for “Eastern Europe models”.

EC-9

PRECAUTIONS

SR20DE

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

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

NCEC0002

The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).

Precautions for On Board Diagnostic (OBD) System of Engine and CVT

NCEC0003

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) I Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL section, “Description”, “HARNESS CONNECTOR”. I Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. I Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the fuel injection system, etc. I Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and TCM (Transmission Control Module) before returning the vehicle to the customer.

EC-10

SR20DE

PRECAUTIONS

Engine Fuel & Emission Control System

Engine Fuel & Emission Control System

NCEC0004

SEF331WB

EC-11

PRECAUTIONS

SR20DE

Precautions

Precautions

NCEC0005

I

Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.

I

When connecting or disconnecting ECM harness connector, use lever as shown. When connecting, fasten connector securely with lever moved until it stops.

I

When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminals when connecting pin connectors.

I

Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-SR-103.

I

After performing each TROUBLE DIAGNOSIS, perform “Overall Function Check” or “DTC Confirmation Procedure”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall Function Check” should be a good result if the repair is completed.

SEF289H

SEF908W

SEF291H

MEF040D

SAT652J

EC-12

SR20DE

PRECAUTIONS

Precautions (Cont’d)

I

When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor.

SEF348N

Wiring Diagrams and Trouble Diagnosis

NCEC0006

When you read Wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section

EC-13

SR20DE

PREPARATION Special Service Tools

Special Service Tools Tool number Tool name

NCEC0007

Description

KV10117100 Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor 1 (front) with 22 mm (0.87 in) hexagon nut

NT379

KV10114400 Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor 2 (rear) a: 22 mm (0.87 in)

NT636

Commercial Service Tool Tool name

NCEC0008

Description

Fuel filler cap adapter

Checking fuel tank vacuum relief valve opening pressure

NT653

EC-14

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

Engine Control Component Parts Location

Engine Control Component Parts Location

NCEC0009

Throttle position sensor IACV-AAC valve

Power steering oil pressure switch

Relay box

EVAP canister Mass air flow sensor and intake air temperature sensor

Heated oxygen sensor 1 (front) EVAP purge volume control solenoid valve

Ignition coil, power transistor & camshaft position sensor built into distributor Crankshaft position sensor

NEF235A

EC-15

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

Engine Control Component Parts Location (Cont’d)

View from under the vehicle .

IACV-AAC valve Knock sensor harness connector

Knock sensor

.

Mass air flow sensor

Drive shaft

View from under the vehicle

Heated oxygen sensor 1 (front) harness connector

Radiator lower hose Crankshaft position sensor (OBD)

Heated oxygen sensor 1 (front)

NEF232A

EC-16

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

Engine Control Component Parts Location (Cont’d) View from under the vehicle Front exhaust tube

ECM

Coolant temperature sensor harness connector

Glove box ECM harness connector Front

Heated oxygen sensor 2 (rear)

Fuel pump harness connector

Heated oxygen sensor 2 (rear)

Fuel tank gauge unit harness connector Under rear seat cushion Front exhaust tube

Power steering oil pressure switch Harness connector EVAP canister (LHD models)

Oil filler cap

EVAP canister purge volume control solenoid valve

SEF188X

EC-17

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

Engine Control Component Parts Location (Cont’d)

Headlamp (Left side)

Intake manifold collector

Fuel pressure regulator

Front

Refrigerant pressure sensor and harness connector

Terminal for ignition coil

Power transistor

Camshaft position sensor, power transistor and ignition coil (built into distributor)

Camshaft position sensor Metal tip of ignition coil tower (Terminal of coil circuit) Terminal for camshaft position sensor and power transistor

NOTE: Power transistor, camshaft position sensor, and ignition coil have to be replaced as a distributor assembly.

SEF189X

EC-18

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE Circuit Diagram

Circuit Diagram

NCEC0010

YEC080A

EC-19

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

System Diagram

System Diagram

NCEC0011

YEC117A

EC-20

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

Vacuum Hose Drawing

Vacuum Hose Drawing

NCEC0012

Refer to “System Diagram” on EC-SR-20 for vacuum control system. NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Rear view (Right side)

Rear view (Left side) Intake manifold collector

Intake manifold collector Throttle body

Fuel pressure regulator To brake booster

Air hose to power steering air valve EVAP purge line to engine

EVAP purge line to engine

Fuel filter

To EVAP canister (RHD models)

Front view EVAP purge volume control solenoid valve

EVAP canister (LHD models)

Power steering air valve

To intake manifold collector

To EVAP canister (LHD models) Air tube for power steering air valve

To EVAP canister (RHD models)

SEF191X

EC-21

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

SR20DE

System Chart

System Chart Input (Sensor) I I I I I I I I I I I I I I I I I I I

Camshaft position sensor Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 (front) Ignition switch Throttle position sensor PNP switch Air conditioner switch Knock sensor Crankshaft position sensor (OBD)*1 Battery voltage Power steering oil pressure switch Vehicle speed sensor or ABS actuator and electric unit (control unit) Intake air temperature sensor Heated oxygen sensor 2 (rear)*2 TCM (Transmission control module)*3 Closed throttle position switch Electrical load Refrigerant pressure sensor

NCEC0013

ECM Function

Output (Actuator)

Fuel injection & mixture ratio control

Injectors

Distributor ignition system

Power transistor

Idle air control system

IACV-AAC valve

Fuel pump control

Fuel pump relay

Heated oxygen sensor 1 (front) monitor & on board diagnostic system

Malfunction indicator (On the instrument panel)

Heated oxygen sensor 1 & 2 (front & rear) heater control

Heated oxygen sensor 1 & 2 heater (front & rear)

EVAP canister purge flow control

EVAP canister purge volume control solenoid valve

Cooling fan control

Cooling fan relay

Air conditioning cut control

Air conditioner relay

*1: These sensors are not used to control the engine system. They are used only for the on board diagnosis. *2: Under normal conditions, this sensor is not for engine control operation. *3: The DTC related to CVT will be sent to ECM.

EC-22

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Multiport Fuel Injection (MFI) System

Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart

NCEC0014 NCEC0014S01

Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed and piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Heated oxygen sensor 1 (front)

Density of oxygen in exhaust gas

Throttle position sensor

Throttle position Throttle valve idle position

PNP switch

Gear position

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Ignition switch

Start signal

Air conditioner switch

Air conditioner operation

Knock sensor

Engine knocking condition

Electrical load

Electrical load signal

Battery

Battery voltage

Power steering oil pressure switch

Power steering operation

Heated oxygen sensor 2 (rear)*

Density of oxygen in exhaust gas

ECM function

Fuel injection & mixture ratio control

Actuator

Injector

* Under normal conditions, this sensor is not for engine control operation.

Basic Multiport Fuel Injection System

NCEC0014S02

The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from both the camshaft position sensor and the mass air flow sensor.

Various Fuel Injection Increase/Decrease Compensation

NCEC0014S03

In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. I During warm-up I When starting the engine I During acceleration I Hot-engine operation I When selector lever is changed from “N” to “D” (CVT models only) I High-load, high-speed operation I During deceleration I During high engine speed operation I During high vehicle speed operation (M/T models) I Extremely high engine coolant temperature

EC-23

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Multiport Fuel Injection (MFI) System (Cont’d)

Mixture Ratio Feedback Control (Closed loop control)

NCEC0014S04

SEF336WA

The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 (front) in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about the heated oxygen sensor 1 (front), refer to EC-SR-144. This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 (rear) is located downstream of the three way catalyst. Even if the switching characteristics of the heated oxygen sensor 1 (front) shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2 (rear).

Open Loop Control

NCEC0014S05

The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. I Deceleration and acceleration I High-load, high-speed operation I Malfunction of heated oxygen sensor 1 (front) or its circuit I Insufficient activation of heated oxygen sensor 1 (front) at low engine coolant temperature I High engine coolant temperature I During warm-up I When starting the engine

Mixture Ratio Self-learning Control

NCEC0014S06

The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1 (front). This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot film) and characteristic changes during operation (i.e., injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from the heated oxygen sensor 1 (front) indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment.

EC-24

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Multiport Fuel Injection (MFI) System (Cont’d)

Fuel Injection Timing

NCEC0014S07

SEF337W

Two types of systems are used. Sequential Multiport Fuel Injection System NCEC0014S0701 Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. Simultaneous Multiport Fuel Injection System NCEC0014S0702 Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The four injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.

Fuel Shut-off

NCEC0014S08

Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.

Distributor Ignition (DI) System DESCRIPTION Input/Output Signal Chart Sensor

NCEC0015 NCEC0015S01

Input Signal to ECM

Camshaft position sensor

Engine speed and piston position

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Throttle position sensor

Throttle position Throttle valve idle position

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Ignition switch

Start signal

Knock sensor

Engine knocking

PNP switch

Gear position

Battery

Battery voltage

ECM function

Actuator

Ignition timPower transistor ing control

EC-25

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Distributor Ignition (DI) System (Cont’d)

System Description

NCEC0015S02

SEF742M

The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map shown above. The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. e.g., N: 1,800 rpm, Tp: 1.50 msec A°BTDC During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. I At starting I During warm-up I At idle I At low battery voltage I During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.

Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor

NCEC0016 NCEC0016S01

Input Signal to ECM

Air conditioner switch

Air conditioner “ON” signal

PNP switch

Neutral position

Throttle position sensor

Throttle valve opening angle

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Refrigerant pressure sensor

Refrigerant pressure

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Power steering oil pressure switch

Power steering operation

ECM function

Air conditioner cut control

System Description

Actuator

Air conditioner relay

NCEC0016S02

This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. I When the accelerator pedal is fully depressed. I When cranking the engine.

EC-26

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Air Conditioning Cut Control (Cont’d)

I I I I

At high engine speeds. When the engine coolant temperature becomes excessively high. When operating power steering during low engine speed or low vehicle speed. When engine speed is excessively low.

Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart

NCEC0017 NCEC0017S01

Sensor

Input Signal to ECM

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

PNP switch

Neutral position

Throttle position sensor

Throttle position

Engine coolant temperature sensor

Engine coolant temperature

Camshaft position sensor

Engine speed

ECM function

Fuel cut control

Actuator

Injectors

If the engine speed is above 3,950 rpm with no load, (for example, in Neutral and engine speed over 4,000 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 1,150 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-SR-23.

Evaporative Emission System DESCRIPTION

NCEC0018

Intake manifold Throttle body

Purge line

EVAP canister purge volume control solenoid valve Relief of vacuum

Sealing gas cap with pressure relief valve and vacuum relief valve

EVAP canister

Air Fuel vapor SEF916W

Fuel tank

The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow

EC-27

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Evaporative Emission System (Cont’d)

rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and idling.

INSPECTION EVAP Canister

NCEC0019 NCEC0019S01

Check EVAP canister as follows: 1. Block port B. Orally blow air through port A. Check that air flows freely through port C with check valve resistance. 2. Block port A. Orally blow air through port B. Check that air flows freely through port C.

SEF917W

Fuel Tank Vacuum Relief Valve (Built into fuel fillerNCEC0019S03 cap) 1. 2.

SEF918W

3.

Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 16.0 - 20.0 kPa (0.16 - 0.20 bar, 0.163 - 0.204 kg/cm2, 2.32 - 2.90 psi) Vacuum: −6.0 to −3.5 kPa (−0.060 to −0.035 bar, −0.061 to −0.036 kg/cm2, −0.87 to −0.51 psi) If out of specification, replace fuel filler cap as an assembly.

Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve NCEC0019S07 Refer to EC-SR-250.

SEF943S

EC-28

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Evaporative Emission System (Cont’d)

EVAPORATIVE EMISSION LINE DRAWING

NCEC0020

NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Rear view (Right side)

Rear view (Left side)

Intake manifold collector Intake manifold collector Throttle body

Fuel pressure regulator

To brake booster

Air hose to power steering air valve EVAP purge line to engine

EVAP purge line to engine

Fuel filter

To EVAP canister (RHD models)

Front view EVAP purge volume control solenoid valve

EVAP canister (LHD models) Power steering air valve

To intake manifold collector

To EVAP canister (LHD models) Air tube for power steering air valve

To EVAP canister (RHD models) SEF193X

EC-29

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

SR20DE

Positive Crankcase Ventilation

Positive Crankcase Ventilation DESCRIPTION

NCEC0022

SEF921W

This system returns blow-by gas to the intake collector. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air duct into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the intake collector under all conditions.

INSPECTION PCV (Positive Crankcase Ventilation) Valve

NCEC0023 NCEC0023S01

With engine running at idle, remove PCV valve from breather separator. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over the valve inlet.

SEC137A

Ventilation Hose 1. 2.

NCEC0023S02

Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

ET277

EC-30

BASIC SERVICE PROCEDURE

SR20DE Fuel Pressure Release

Fuel Pressure Release

NCEC0024

Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.

WITH CONSULT-II 1. 2. 3. PEF823K

4.

WITHOUT CONSULT-II Fuel pump fuse

1. 2. 3. 4.

NCEC0024S01

Start engine. Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode with CONSULT-II. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. NCEC0024S02

Remove fuse for fuel pump. Refer to fuse block cover for fuse location. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF and reconnect fuel pump fuse.

Fuel pump relay

Data link connector

SEF192X

Fuel Pressure Check I I Fuel filter

SEF194X

I I I 1. 2. 3. 4. 5.

NCEC0025

When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. Release fuel pressure to zero. Disconnect fuel hose between fuel filter and fuel tube (engine side). Install pressure gauge between fuel filter and fuel tube. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. At idle speed: With vacuum hose connected Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi)

EC-31

BASIC SERVICE PROCEDURE

SR20DE

Fuel Pressure Regulator Check

If results are unsatisfactory, perform Fuel Pressure Regulator Check, EC-SR-32.

Fuel Pressure Regulator Check

NCEC0026

1.

SEF718B

Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 2. Plug intake manifold with a rubber cap. 3. Connect variable vacuum source to fuel pressure regulator. 4. Start engine and read indication of fuel pressure gauge as vacuum is changed. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. I Do not reuse O-ring.

Injector REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. I I I 6. I I I I I I SEF927W

I 7. I 8. 9.

NCEC0027

Release fuel pressure to zero. Disconnect fuel hoses and injector harness connectors. Remove fuel tube assemblies with fuel injectors. Expand and remove clips securing fuel injectors. Extract fuel injectors straight from fuel tubes. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble or adjust fuel injectors. Install fuel injectors with extra care for O-rings. Do not reuse O-rings. Use bare hands to install O-rings. Do not wear gloves. Apply a coat of new engine oil (with a low viscosity of 5W-30, etc.) to O-rings before installation. Do not use solvent to clean O-rings and other parts. Make sure that O-rings and other parts are clean and free from foreign particles. Be careful not to damage O-rings with service tools, clip or finger nails. Do not expand or twist O-rings. If stretched, do not insert them into fuel tubes immediately after stretching. Always insert O-rings straight into fuel tubes. Do not tilt or rotate them during installation. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation. Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips.

EC-32

BASIC SERVICE PROCEDURE

SR20DE Injector (Cont’d)

I

Fuel tube

O-ring

Discard old clips; replace with new ones.

10. Install injectors with fuel tube assembly to intake manifold. I Pay extra care to prevent O-rings from being scratched by sharp edges. I Apply a coat of new engine oil to O-rings before installation.

Spacer Clip

Injector Apply engine oil.

SEF195X

SEF196X

11. Tighten fuel tube assembly mounting bolts in numerical sequence (indicated in the Figure at left) and in two stages. : Tightening torque N⋅m (kg-m, ft-lb) 1st stage: 9.4 - 10.7 (0.95 - 1.10, 83 - 95) 2nd stage: 21 - 26 (2.1 - 2.7, 16 - 19) 12. Insert fuel hoses into fuel tubes so that ends of fuel hoses butt up against fuel tubes; fasten with clamps, avoiding bulges. I Lubricate fuel hoses with a smear of silicone oil. 13. Reinstall any parts removed in reverse order of removal. CAUTION: After properly connecting fuel hose to injector and fuel tube assembly, check connection for fuel leakage.

EC-33

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment

NCEC0028

PREPARATION I a) b) c) d) e) f) g) h) i) j) k) I I I I I I I a) b) c) I

NCEC0028S01

Make sure that the following parts are in good order. Battery Ignition system Engine oil and coolant levels Fuses ECM harness connector Vacuum hoses Air intake system (Oil filler cap, oil level gauge, etc.) Fuel pressure Engine compression Throttle valve EVAP system On models equipped with air conditioner, checks should be carried out while the air conditioner is “OFF”. When checking idle speed on models equipped with CVT, ignition timing and mixture ratio, checks should be carried out while shift lever is in “P” or “N” position. When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. Turn off headlamps, heater blower, rear window defogger. On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. Keep front wheels pointed straight ahead. If engine stops immediately after starting or idle condition is unstable, perform the following to initialize IACV-AAC valve: Stop engine and wait 9 seconds. Turn ignition “ON” and wait 1 second. Turn ignition “OFF” and wait 9 seconds. Make the check after the cooling fan has stopped.

EC-34

SR20DE

BASIC SERVICE PROCEDURE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

Overall Inspection Sequence

NCEC0028S0101

INSPECTION

Perform diagnostic test mode II (Self-diagnostic results).

NG

Check ignition timing and idle speed.

Idle air volume learning.* COMPLETE

INCOMPLETE H Find reason for incompleteness, and remove.*

OK

Check heated oxygen sensor 1 (front) function.

Repair or replace.

NG

Check heated oxygen sensor 1 (front) harness.

NG Repair or replace harness.

OK

OK

Check CO%.

Replace front heated oxygen sensor.

NG

Check emission control parts and repair or replace if necessary.

NG

Check front heated oxygen sensor function.

OK

INSPECTION END

SEF104X

*: Refer to EC-SR-46.

EC-35

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

INSPECTION PROCEDURE 1

NCEC0028S02

INSPECTION START

1. Visually check the following: I Air cleaner clogging I Hoses and duct for leaks I Electrical connectors I Gasket (intake manifold, cylinder head, exhaust system) I Throttle valve and throttle position sensor operation 2. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge. Ensure engine speed stays below 1,000 rpm.

SEF935W

3. Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load. 4. Perform the Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-SR-61.

SAT652J

OK or NG OK

©

I GO TO 2. (With CONSULT-II) I GO TO 3. (Without CONSULT-II)

NG

©

1. Repair or replace components as necessary. 2. GO TO 2. (With CONSULT-II) 3. GO TO 3. (Without CONSULT-II)

EC-36

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

2

CHECK IGNITION TIMING

With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine two or three times under no-load, then run engine at idle speed for about 1 minute.

SEF978U

3. Select “IGNITION TIMING ADJ” in WORK SUPPORT mode. 4. Touch “START”.

PEF546N

5. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 6. Check ignition timing with a timing light.

BTDC

White painting

AEC804

15°±2° BTDC (in “P” or “N” position for CVT)

OK

©

I GO TO 5. (With CONSULT-II) I GO TO 6. (Without CONSULT-II)

NG

©

1. Perform “Idle air volume learning”. Refer to EC-SR-46 2. If still NG, GO TO 4.

EC-37

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

3

CHECK IGNITION TIMING

Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine two or three times under no-load, then run engine at idle speed for about 1 minute.

SEF978U

3. Turn off engine and disconnect throttle position sensor harness connector (CVT models only). Throttle position sensor harness connector

Throttle body

Closed throttle position switch harness connector (CVT models)

SEF197X

4. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 5. Check ignition timing with a timing light. BTDC

White painting

AEC804

15°±2° BTDC (in “P” or “N” position for CVT) OK or NG OK

©

GO TO 5.

NG

©

1. Perform “Idle air volume learning”. Refer to EC-SR-46. 2. If still NG, GO TO 4.

EC-38

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

4

ADJUST IGNITION TIMING

With CONSULT-II 1. Adjust ignition timing to the specified value by turning distributor after loosening bolts which secure distributor. Without CONSULT-II 1. Adjust ignition timing to the specified value by turning distributor after loosening bolts which secure distributor. 2. Turn off engine and connect throttle position sensor harness connector to throttle position sensor. (CVT models only) Throttle position sensor harness connector

Throttle body

Closed throttle position switch harness connector (CVT models) SEF197X

Models with CONSULT-II

©

GO TO 2.

Models without CONSULT-II

©

GO TO 3.

5

CHECK TARGET IDLE SPEED

With CONSULT-II 1. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II.

NEF059A

750±50 rpm (in “P” or “N” position for CVT) OK or NG OK

©

GO TO 8.

NG

©

1. Perform “Idle air volume learning”. Refer to EC-SR-46. 2. If still NG, GO TO 7.

EC-39

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

6

CHECK TARGET IDLE SPEED

Without CONSULT-II 1. Turn off engine and connect throttle position sensor harness connector (CVT models only). Throttle position sensor harness connector

Throttle body

Closed throttle position switch harness connector (CVT models) SEF197X

2. Start engine. 3. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. 4. Check target idle speed. 750±50 rpm (in “P” or “N” position for CVT) OK or NG OK

©

GO TO 8.

OK (Ignition timing NG)

©

GO TO 7.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. 1. Check closed throttle position switch idle position. Refer to EC-SR-84. 2. Check IACV-AAC valve and replace if necessary. Refer to EC-SR-263. 3. Check IACV-AAC valve harness and repair if necessary. Refer to EC-SR-263. 4. Perform “Idle air volume learning”. Refer to EC-SR-46. 5. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.)

©

GO TO 8.

EC-40

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

8

CHECK HEATED OXYGEN SENSOR 1 (FRONT) SIGNAL

With CONSULT-II 1. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. 2. Run engine at about 2,000 rpm for about 2 minutes under no-load. 3. Maintain engine at 2,000 rpm under no-load (engine is warmed up to normal operating temperature) and check that the monitor fluctuates between “LEAN” and “RICH” more than five times during 10 seconds.

SEF820Y

1 cycle: RICH → LEAN → RICH 2 cycles: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II 1. Set “Heated oxygen sensor 1 (front) monitor” in the Diagnostic Test Mode II. (See page EC-SR-58.) Short terminals between “IGN” and “CHK” for 2 seconds or more. Then open the circuit.

SEF945W

2. Run engine at about 2,000 rpm for about 2 minutes under no-load (engine is warmed up to normal operating temperature). 3. Maintain engine at 2,000 rpm under no-load and check that MI goes on more than five times during 10 seconds.

SAT652J

OK or NG OK

©

INSPECTION END

NG

©

GO TO 9.

EC-41

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

9 1. 2. 3. 4.

CHECK HEATED OXYGEN SENSOR 1 (FRONT) HARNESS Turn off engine and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (front) harness connector. Then connect harness connector terminal for heated oxygen sensor 1 (front) to ground with a jumper wire. Heated oxygen sensor 1 (front) harness connector

MEF031DA

5. Check for continuity between terminal 62 of ECM harness connector and body ground. Continuity exists...OK Continuity does not exist...NG OK or NG OK

©

1. Connect ECM harness connector to ECM. 2. GO TO 10.

NG

©

1. Repair or replace harness. 2. GO TO 5. (With CONSULT-II) 3. GO TO 6. (Without CONSULT-II)

EC-42

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

10 1. 2. 3. 4.

PREPARATION FOR “CO” % CHECK With CONSULT-II Connect ECM harness connector to ECM. Connect battery ground cable. Select “ENGINE COOLANT TEMP” in “ACTIVE TEST” mode. Set “COOLANT TEMP” to 5°C (41°F) by touching “Qu” and “Qd” and “UP”, “DOWN”.

NEF061A

Without CONSULT-II 1. Connect ECM harness connector to ECM. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect a resistor (4.4 kΩ) between terminals of engine coolant temperature sensor harness connector.

Engine coolant temperature sensor harness connector

4.4 kΩ resistor

4. Connect battery ground cable.

©

GO TO 11.

EC-43

SEF053RA

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

11

CHECK “CO” %

1. Start engine and warm it up until engine coolant temperature indicator points to middle of gauge. (Be sure to start engine after setting “COOLANT TEMP” or installing a 4.4 kΩ resistor.)

SEF935W

2. Rev engine two or three times under no-load, then run engine at idle speed.

SEF978U

3. Check “CO”%. Idle CO: Less than 11% and engine runs smoothly. 4. Without CONSULT-II After checking CO%, stop engine and a. Disconnect the resistor from terminals of engine coolant temperature sensor harness connector. b. Connect engine coolant temperature sensor harness connector to engine coolant temperature sensor. OK or NG OK

©

GO TO 12.

NG

©

GO TO 13.

12

CHECK HEATED OXYGEN SENSOR 1 (FRONT) SIGNAL

With CONSULT-II 1. Replace heated oxygen sensor 1 (front). 2. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. 3. Maintain engine at 2,000 rpm under no-load (engine is warmed up to normal operating temperature.). Check that the monitor fluctuates between “LEAN” and “RICH” more than five times during 10 seconds. 1 cycle: RICH → LEAN → RICH 2 cycles: RICH → LEAN → RICH → LEAN → RICH Without CONSULT-II 1. Replace heated oxygen sensor 1 (front). 2. Set “Heated oxygen sensor 1 (front) monitor” in the Diagnostic Test Mode II. (See page EC-SR-61.) 3. Maintain engine at 2,000 rpm under no-load. Check that the malfunction indicator goes on and off more than five times during 10 seconds. OK or NG OK

©

GO TO 5. (With CONSULT-II) GO TO 6. (Without CONSULT-II)

NG

©

GO TO 13.

EC-44

BASIC SERVICE PROCEDURE

SR20DE

Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d)

13

DETECT MALFUNCTIONING PART

1. Connect heated oxygen sensor 1 (front) harness connector to heated oxygen sensor 1 (front). 2. Check fuel pressure regulator. Refer to EC-SR-32. 3. Check mass air flow sensor and its circuit. Refer to EC-SR-120. 4. Check injector and its circuit. Refer to EC-SR-302. Clean or replace if necessary. 5. Check engine coolant temperature sensor and its circuit. Refer to EC-SR-132. 6. Check ECM function by substituting another known good ECM. (ECM may be the cause of a problem, but this is rarely the case.)

©

GO TO 5. (With CONSULT-II) GO TO 6. (Without CONSULT-II)

I

If a vehicle contains a part which is operating outside of design specifications with no MI illumination, the part shall not be replaced prior to emission testing unless it is determined that the part has been tampered with or abused in such a way that the diagnostic system cannot reasonably be expected to detect the resulting malfunction.

EC-45

BASIC SERVICE PROCEDURE

SR20DE

Idle Air Volume Learning

Idle Air Volume Learning

NCEC0541

DESCRIPTION

NCEC0541S01

“Idle Air Volume Learning” is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: I Each time IACV-AAC valve, throttle body or ECM is replaced. I Idle speed or ignition timing is out of specification.

PRE-CONDITIONING SEF712X

SEF713X

OPERATION PROCEDURE With CONSULT-II SEF714X

NCEC0541S04

Before performing “Idle Air Volume Learning”, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. I Battery voltage: More than 12.9V (At idle) I Engine coolant temperature: 70 - 94°C (158 - 201°F) I PNP switch: ON I Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. I Cooling fan motor: Not operating I Steering wheel: Neutral (Straight-ahead position) I Vehicle speed: Stopped I Transmission : Warmed up For CVT models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “CVT” system indicates less than 0.9V. For CVT models without CONSULT-II and M/T models, drive vehicle for 10 minutes.

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

8.

NCEC0541S02 NCEC0541S0201

Start engine and warm it up to normal operating temperature. Check that all items listed under the topic “Pre-Conditioning” (previously mentioned) are in good order. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and allow it to idle for at least 28 seconds. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. Touch “START” and wait 20 seconds. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “INCMP” is displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the problem by referring to the NOTE below. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications.

ITEM

SPECIFICATION

Idle speed

750 ± 50rpm (in “P” or “N” position for CVT)

Ignition timing

15 ± 2° BTDC

EC-46

BASIC SERVICE PROCEDURE

SR20DE Idle Air Volume Learning (Cont’d)

Throttle body

Throttle position sensor harness connector

Without CONSULT-II 1. 2. 3. 4. 5.

Closed throttle position switch harness connector (CVT models) SEF197X

6. 7.

8.

NCEC0541S0202

Start engine and warm it up to normal operating temperature. Check that all items listed under the topic “Pre-Conditioning” (previously mentioned) are in good order. Turn ignition switch “OFF” and wait at least 9 seconds. Start the engine and allow it to idle for at least 28 seconds. Disconnect throttle position sensor harness connector (brown), then re-connect it within 5 seconds. (CVT models only) Wait 20 seconds. Make sure that the idle speed is within specifications. If not, the result will be incomplete. In this case, find the cause of the problem by referring to the NOTE below. Rev up the engine two or three times. Make sure that idle speed and ignition timing are within specifications.

ITEM

SPECIFICATION

Idle speed

750 ± 50rpm (in “P” or “N” position for CVT)

Ignition timing

15 ± 2° BTDC

NOTE: I If idle air volume learning cannot be performed successfully, proceed as follows: a) Check the throttle valve is fully closed. b) Check that downstream of throttle valve is free from air leakage. c) Adjust closed throttle position switch and reset memory. (Refer to Basic Inspection, EC-SR-84.) d) When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the problem. e) If any of the following conditions occur after the engine has started, eliminate the cause of the problem and perform “Idle air volume learning” all over again: I Engine stalls. I Erroneous idle. I Blown fuses related to the IACV-AAC valve system.

EC-47

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction

Introduction

NCEC0029

The ECM has an on board diagnostic system which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Diagnostic Trouble Code (DTC)

Mode 3 of ISO 15031-5

Freeze Frame data

Mode 2 of ISO 15031-5

System Readiness Test (SRT) code

Mode 1 of ISO 15031-5

1st Trip Diagnostic Trouble Code (1st Trip DTC)

Mode 7 of ISO 15031-5

1st Trip Freeze Frame data Test values and Test limits

Mode 6 of ISO 15031-5

Calibration ID

Mode 9 of ISO 15031-5

The above information can be checked using procedures listed in the table below. X: Applicable

—: Not applicable

DTC

1st trip DTC

Freeze Frame data

1st trip Freeze Frame data

SRT code

Test value

ECM*3

X

X*1

—

—

—

—

CONSULT-II*4

X

X

X

X

X

—

GST*4

X

X*2

X

—

X

X

*1: *2: *3: *4:

When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display. In diagnostic test mode II (Self-diagnostic results), DTC is displayed on MI. DTC uses a set of four digit numbers. In SELF-DIAGNOSTIC RESULTS mode, DTC is displayed. DTC uses “P” and a set of four digit numbers.

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-SR-93.)

Two Trip Detection Logic

NCEC0030

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage <1st trip>. If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored <2nd trip>. The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. X: Applicable MI

DTC

1st trip

Items

—: Not applicable 1st trip DTC

2nd trip 1st trip displaying

2nd trip displaying

1st trip displaying

2nd trip displaying

—

X

—

X

—

X

—

—

X

—

—

X

—

—

X*1

—

X*1

—

—

—

X

—

X

X

X

Blinking

Lighting up

Blinking

Lighting up

Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) is being detected

X

—

—

Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 (0300 - 0304) has been detected

—

—

Fail-safe items (Refer to ECSR-93.)

—

Except above

—

*1: Except “ECM”.

EC-48

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information

Emission-related Diagnostic Information DTC AND 1ST TRIP DTC

NCEC0031 NCEC0031S01

The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory. Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”. Refer to EC-SR-56. For malfunctions in which 1st trip DTCs are displayed, refer to EC-SR-54. These items are required by legal regulations to continuously monitor the system/component. In addition, the items monitored non-continuously are also displayed on CONSULT-II. 1st trip DTC is specified in Mode 7 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a problem. However, 1st trip DTC detection will not prevent the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests. When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in “Work Flow” procedure Step II, refer to page EC-SR-82. Then perform “DTC Confirmation Procedure” or “Overall Function Check” to try to duplicate the problem. If the malfunction is duplicated, the item requires repair.

How to read DTC and 1st Trip DTC

NCEC0031S0101

DTC and 1st trip DTC can be read by the following methods. 1) No Tools The number of blinks of MI in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0340, 1320, 0705, 0750, etc. These DTCs are controlled by NISSAN. 2) With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc. These DTCs are prescribed by ISO 15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I Output of a DTC indicates a malfunction. However, Mode II and GST do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be “0”. If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”.

1st trip DTC display

DTC display

NEF065A

EC-49

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d)

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

NCEC0031S02

The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed and absolute pressure sensor at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For details, see EC-SR-71. Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1

Items Freeze frame data

2 3

Misfire — DTC: P0300 - P0304 (0300 - 0304) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172) Except the above items (Includes CVT related items)

1st trip freeze frame data

For example, the CVT malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated from the CVT malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the ECM memory. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in “HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION”. Refer to EC-SR-56.

SYSTEM READINESS TEST (SRT) CODE

NCEC0031S03

System Readiness Test (SRT) code is specified in Mode 1 of ISO 15031-5. It indicates whether the self-diagnostic tests for non-continuously monitored items have been completed or not. Inspection/Maintenance (I/M) tests of the on board diagnostic (OBD) II system may become the legal requirements in some states/areas. All SRT codes must be set in this case. Unless all SRT codes are set, conducting the I/M test may not be allowed. SRT codes are set after self-diagnosis has been performed one or more times. This occurs regardless of whether the diagnosis is in “OK” or “NG”, and whether or not the diagnosis is performed in consecutive trips. The following table lists the four SRT items (14 test items) for the ECM used in P11 models. SRT items

Self-diagnostic test items

Catalyst monitoring

I Three way catalyst function P0420 (0420)

Oxygen sensor monitoring

I I I I I I I I I

Oxygen sensor heater monitoring

I Heated oxygen sensor 1 (front) heater P0135 (0135) I Heated oxygen sensor 2 (rear) heater P0141 (0141)

Heated Heated Heated Heated Heated Heated Heated Heated Heated

oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen oxygen

sensor sensor sensor sensor sensor sensor sensor sensor sensor

EC-50

1 1 1 1 1 2 2 2 2

(front) (Circuit) P0130 (0130) (front) (Lean shift monitoring) P0131 (0131) (front) (Rich shift monitoring) P0132 (0132) (front) (Response monitoring) P0133 (0133) (front) (High voltage) P0134 (0134) (rear) (Min. voltage monitoring) P0137 (0137) (rear) (Max. voltage monitoring) P0138 (0138) (rear) (Response monitoring) P0139 (0139) (rear) (High voltage) P0140 (0140)

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d)

Together with the DTC, the SRT code is cleared from the ECM memory using the method described later (Refer to EC-SR-56). In addition, after engine control components/system are repaired or if the battery terminals remain disconnected for more than 24 hours, all SRT codes may be cleared from the ECM memory.

How to Display SRT Code 1.

NCEC0031S0301

With CONSULT-II Selecting “SRT STATUS” in “DTC CONFIRMATION” mode with CONSULT-II. For items whose SRT codes are set, a “CMPLT” is displayed on the CONSULT-II screen; for items whose SRT codes are not set, “INCMP” is displayed as shown below.

NEF249A

2.

With GST Selecting Mode 1 with GST (Generic Scan Tool)

How to Set SRT Code

NCEC0031S0302

To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The driving pattern should be performed one or more times to set all SRT codes.

EC-51

HO2S HTR

HO2S

EC-52

Pattern 1

*1

Engine coolant temperature becomes 70°C (158°F). Engine start [Engine coolant temperature is below 50°C (122°F).]

0 km/h (0 MPH)

26 - 96 km/h (53 - 60 MPH)

*2

HO2S2 HTR

HO2S1 HTR

HO2S2

Keep idling

TW CATALYST SYS

CATALYST

HO2S1

Self-diagnostic test item (CONSULT-II screen term)

Zone A

Zone B

Pattern 2

Note: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws. Refer to next page for more information and explanation of chart.

SRT item (CONSULT-II screen term)

Driving pattern

Engine stop

(minutes)

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION SR20DE

Emission-related Diagnostic Information (Cont’d)

Driving Pattern NCEC0031S0303

NEF234A

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Emission-related Diagnostic Information (Cont’d)

I

The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc. Zone A refers to the range where the time required, for the diagnosis under normal conditions*, is the shortest. Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed within zone A. *: Normal conditions refer to the following: − − − −

Sea level Flat road Ambient air temperature: 20 - 30°C (68 - 86°F) Diagnosis is performed as quickly as possible under normal conditions. Under different conditions [For example: ambient air temperature other than 20 - 30°C (68 - 86°F)], diagnosis may also be performed.

Pattern 1: I The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminals 70 and 58 is 3.0 - 4.3V). I The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminals 70 and 58 is lower than 1.4V). Pattern 2: I When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended. *1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH) again. *2: Checking the vehicle speed with CONSULT-II or GST is advised. Suggested transmission gear position for CVT models Set the selector lever in the “D” position with “SPORTS MODE SW” “OFF” or without “MANUAL MODE”. Suggested upshift speeds for M/T models Shown below are suggested vehicle speeds for shifting into a higher gear. These suggestions relate to fuel economy and vehicle performance. Actual upshift speeds will vary according to road conditions, the weather and individual driving habits. Gear change

ACCEL shift point km/h (MPH)

1st to 2nd

15 (9)

2nd to 3rd

35 (22)

3rd to 4th

50 (31)

4th to 5th

70 (43)

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

NCEC0031S04

The following is the information specified in Mode 6 of ISO 15031-5. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. Items for which these data (test value and test limit) are displayed are the same as SRT code items (6 test items). These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. X: Applicable

—: Not applicable

Test value (GST display) SRT item

CATALYST

Self-diagnostic test item

Test limit

Application

01H

Max.

X

81H

Min.

X

TID

CID

01H 02H

Three way catalyst function

EC-53

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d) Test value (GST display) SRT item

Self-diagnostic test item

Heated oxygen sensor 1 (front)

HO2S

Heated oxygen sensor 2 (rear)

Heated oxygen sensor 1 (front) heater

Test limit

Application

04H

Max.

X

0AH

84H

Min.

X

0BH

04H

Max.

X

0CH

04H

Max.

X

0DH

04H

Max.

X

19H

86H

Min.

X

1AH

86H

Min.

X

1BH

06H

Max.

X

1CH

06H

Max.

X

29H

08H

Max.

X

2AH

88H

Min.

X

2DH

0AH

Max.

X

2EH

8AH

Min.

X

TID

CID

09H

HO2S HTR Heated oxygen sensor 2 (rear) heater

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

NCEC0031S05

X: Applicable DTC*4 Items (CONSULT-II screen terms)

SRT code

Test value/Test limit 1st trip DTC*4 (GST only)

—: Not applicable Reference page

CONSULT-II GST*2

ECM*1

NO SELF DIAGNOSTIC FAILURE INDICATED

P0000

0000

—

—

—

—

MAF SEN/CIRCUIT

P0100

0100

—

—

X

EC-SR-120

AIR TEMP SEN/CIRC *5

P0110

0110

—

—

X

EC-SR-127

COOLANT T SEN/CIRC

P0115

0115

—

—

X

EC-SR-132

THRTL POS SEN/CIRC

P0120

0120

—

—

X

EC-SR-137

HO2S1 (B1)

P0130

0130

X

X

X*3

EC-SR-144

HO2S1 (B1)*5

P0131

0131

X

X

X*3

EC-SR-150

HO2S1 (B1)*5

P0132

0132

X

X

X*3

EC-SR-156

HO2S1 (B1)*5

P0133

0133

X

X

X*3

EC-SR-162

HO2S1 (B1)*5

P0134

0134

X

X

X*3

EC-SR-170

HO2S1 HTR (B1)*5

P0135

0135

X

X

X*3

EC-SR-175

HO2S2 (B1) *5

P0137

0137

X

X

X*3

EC-SR-180

HO2S2 (B1) *5

P0138

0138

X

X

X*3

EC-SR-187

HO2S2 (B1) *5

P0139

0139

X

X

X*3

EC-SR-194

HO2S2 (B1) *5

P0140

0140

X

X

X*3

EC-SR-201

HO2S2 HTR (B1) *5

P0141

0141

X

X

X*3

EC-SR-207

FUEL SYS LEAN/BK1*5

P0171

0171

—

—

X

EC-SR-212

FUEL SYS RICH/BK1 *5

P0172

0172

—

—

X

EC-SR-218

MULTI CYL MISFIRE *5

P0300

0300

—

—

X

EC-SR-224

EC-54

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d) DTC*4 Items (CONSULT-II screen terms)

SRT code

Test value/Test limit 1st trip DTC*4 (GST only)

Reference page

CONSULT-II GST*2

ECM*1

CYL 1 MISFIRE *5

P0301

0301

—

—

X

EC-SR-224

CYL 2 MISFIRE *5

P0302

0302

—

—

X

EC-SR-224

CYL 3 MISFIRE *5

P0303

0303

—

—

X

EC-SR-224

CYL 4 MISFIRE *5

P0304

0304

—

—

X

EC-SR-224

KNOCK SEN/CIRC-B1

P0325

0325

—

—

—

EC-SR-230

CPS/CIRCUIT (OBD) *5

P0335

0335

—

—

X

EC-SR-234

CAM POS SEN/CIRC

P0340

0340

—

—

X

EC-SR-239

TW CATALYST SYS-B1 *5

P0420

0420

X

X

X*3

EC-SR-246

PURG VOLUME CONT/V *5

P0443

0443

—

—

X

EC-SR-250

VEH SPEED SEN/CIRC

P0500

0500

—

—

X

EC-SR-255

IACV/AAC VLV/CIRC *5

P0505

0505

—

—

X

EC-SR-263

CLOSED TP SW/CIRC *5 *6

P0510

0510

—

—

X

EC-SR-271

ECM *5

P0605

0605

—

—

X

EC-SR-277

PNP SW/CIRC *5

P0705

0705

—

—

X

AT section

ATF TEMP SEN/CIRC *5

P0710

0710

—

—

X

AT section

IN PY SPD SEN/CIRC *5

P0715

0715

—

—

X

AT section

VEH SPD SEN/CIR AT *5

P0720

0720

—

—

X

AT section

ENGINE SPEED SIG *5

P0725

0725

—

—

X

AT section

TCC SOLENOID/CIRC *5

P0740

0740

—

—

X

AT section

L/PRESS SOL/CIRC *5

P0745

0745

—

—

X

AT section

ENG OVER TEMP

P1217

1217

—

—

X

EC-SR-279

CPS/CIRC (OBD) COG *5

P1336

1336

—

—

X

EC-SR-290

A/T DIAG COMM LINE *5

P1605

1605

—

—

X

EC-SR-295

TP SEN/CIRC A/T *5

P1705

1705

—

—

X

AT section

P-N POS SW/CIRCUIT *5

P1706

1706

—

—

X

EC-SR-298

STEP MOTOR CIRC *5

P1777

1777

—

—

X

AT section

STEP MOTOR FNC *5

P1778

1778

—

—

X

AT section

LINE PRESSURE SEN *5

P1791

1791

—

—

X

AT section

*1: *2: *3: *4: *5: *6:

In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN. These numbers are prescribed by ISO 15031-6. These are not displayed with GST. 1st trip DTC No. is the same as DTC No. Not available for “Eastern Europe models”. CVT models only

EC-55

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d)

HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC (With CONSULT-II)

NCEC0031S06 NCEC0031S0601

NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), skip steps 2 through 4. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again. 2. Turn CONSULT-II “ON” and touch “A/T”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) will be erased.] Then touch “BACK” twice. 5. Touch “ENGINE”. 6. Touch “SELF-DIAG RESULTS”. 7. Touch “ERASE”. (The DTC in the ECM will be erased.) I If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module).

EC-56

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d)

SEF950W

The emission-related diagnostic information can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II.

How to Erase DTC (With GST)

NCEC0031S0602

NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), skip step 2. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” (engine stopped) again. 2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Select Mode 4 with GST (Generic Scan Tool). The emission-related diagnostic information can be erased by selecting Mode 4 with GST (Generic Scan Tool).

EC-57

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Emission-related Diagnostic Information (Cont’d)

How to Erase DTC (No Tools)

NCEC0031S0603

NOTE: If the diagnostic trouble code is not for CVT related items (see EC-SR-6), skip step 2. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 9 seconds and then turn it “ON” again. 2. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-SR61.) The emission-related diagnostic information can be erased by changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by using the data link connector. (Refer to EC-SR-61.) NOTE: I If the battery is disconnected, the emission-related diagnostic information will be lost after approx. 24 hours. I Erasing the emission-related diagnostic information using CONSULT-II or GST is easier and quicker than switching the mode using the data link connector. I The following data are cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures.

Malfunction Indicator (MI) NATS (NISSAN ANTI-THEFT SYSTEM)

SEF543X

I I I

If the security indicator lights up with the ignition switch in the “ON” position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to NATS (Nissan Anti-Theft System) in EL section. Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedure of NATS initilialization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.

EC-58

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Malfunction Indicator (MI) (Cont’d)

DESCRIPTION

NCEC0032

SAT652J

The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. I If the MI does not light up, refer to EL section (“WARNING LAMPS”) or see EC-SR-329. 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction.

On Board Diagnostic System Function

NCEC0032S01

The on board diagnostic system has the following four functions. Diagnostic Test Mode I 1. BULB CHECK: This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit and ECM test mode selector. (See the following page.) 2. MALFUNCTION WARNING: This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MI in the 1st trip. I “Misfire (Possible three way catalyst damage)” I “Closed loop control” I Fail-safe mode Diagnostic Test Mode II 3. SELF-DIAGNOSTIC RESULTS: This function allows DTCs and 1st trip DTCs to be read. 4. HEATED OXYGEN SENSOR 1 (FRONT) MONITOR: This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1 (front), to be read. MI Flashing without DTC NCEC0032S0101 If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM test mode following “HOW TO SWITCH DIAGNOSTIC TEST MODES”. How to switch the diagnostic test (function) modes, and details of the above functions are described later. (Refer to EC-SR-61.) Condition

Diagnostic Test Mode I

Diagnostic Test Mode II

BULB CHECK

SELF-DIAGNOSTIC RESULTS

MALFUNCTION WARNING

HEATED OXYGEN SENSOR 1 (FRONT) MONITOR

Engine stopped Ignition switch in “ON” position Engine running

The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data

EC-59

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator (MI) (Cont’d)

4) 5) 6) 7) 8)

1st trip freeze frame data System readiness test (SRT) codes Test values Distance traveled while MI is activated Others

EC-60

SR20DE

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Malfunction Indicator (MI) (Cont’d)

How to Switch Diagnostic Test Modes

NCEC0032S02

NG

Check MI circuit. *1

Turn ignition switch “ON” (Do not start engine.)

Repair harness or connector.

OK

Mode I - MALFUNCTION INDICATOR LAMP CHECK. *2 MI should come on.

NG Diagnostic Test Mode I — MALFUNCTION WARNING Start engine.

NG

NG

Repair harness or connectors.

Check MI and DDL circuits. *3

Data link connector

OK OK

Connect CHK and IGN terminals with a suitable harness. MI should come off.

Check ECM fail-safe. *4 OK

OK Wait at least 2 seconds.

Data link connector

Disconnect the suitable harness between CHK and IGN terminals.

DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS (ERASING ECM MEMORY)

Data link connector

Start engine

Diagnostic Test Mode II — HEATED OXYGEN SENSOR 1 (FRONT) MONITOR

● Switching the modes is not possible when the

engine is running. ● When ignition switch is turned off during

diagnosis, power to ECM will drop after approx. 9 seconds. The diagnosis will automatically return to Diagnostic Test Mode I. Wait at least 2 seconds.

Data link connector

*1: EC-SR-329 *2: EC-SR-59

If the suitable harness is disconnected at this time, the diagnostic trouble code will be erased from the backup memory in the ECM.

*3: EC-SR-329

EC-61

*4: EC-SR-93

SEF951W

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Malfunction Indicator (MI) (Cont’d)

Diagnostic Test Mode I — Bulb Check

NCEC0032S03

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the MI bulb. Refer to EL section (“WARNING LAMPS”) or see EC-SR-329.

Diagnostic Test Mode I — Malfunction Warning MI

I

NCEC0032S04

Condition

ON

When the malfunction is detected or the ECM’s CPU is malfunctioning.

OFF

No malfunction.

These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS).

Diagnostic Test Mode II — Self-diagnostic Results

NCEC0032S05

In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using the CONSULT or GST. A DTC will be used as an example for how to read a code.

SEF952W

A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second)-OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0 second OFF. In other words, the latter numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8 second off. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC “0000” refers to no malfunction. (See TROUBLE DIAGNOSIS — INDEX, EC-SR-6.) How to Erase Diagnostic Test Mode II (Self-diagnostic results) NCEC0032S0501 The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODES”.) I If the battery is disconnected, the DTC will be lost from the backup memory after approx. 24 hours. I Be careful not to erase the stored memory before starting trouble diagnoses.

EC-62

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Malfunction Indicator (MI) (Cont’d)

Diagnostic Test Mode II — Front Heated Oxygen Sensor Monitor

NCEC0032S06

In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1 (front). MI

Fuel mixture condition in the exhaust gas

ON

Lean

OFF

Rich

*Remains ON or OFF

Any condition

Air fuel ratio feedback control condition Closed loop system Open loop system

*: Maintains conditions just before switching to open loop.

To check the heated oxygen sensor 1 (front) function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no-load.

OBD System Operation Chart

NCEC0033

RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS I I I I

I

NCEC0033S01

When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are stored in the ECM memory. When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are stored in the ECM memory, and the MI will come on. For details, refer to “Two Trip Detection Logic” on EC-SR-48. The MI will go off after the vehicle is driven 3 times with no malfunction. The drive is counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting, the counter will reset. The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A) without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven. The 1st trip DTC is not displayed when the self-diagnosis results in “OK” for the 2nd trip.

SUMMARY CHART Items MI (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear)

NCEC0033S02

Fuel Injection System

Misfire

Other

3 (pattern B)

3 (pattern B)

3 (pattern B)

80 (pattern C)

80 (pattern C)

40 (pattern A)

1 (pattern C), *1

1 (pattern C), *1

1 (pattern B)

*1, *2

*1, *2

1 (pattern B)

For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-SR-65. For details about patterns “A” and “B” under “Other”, see EC-SR-67. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip.

EC-63

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” <EXHAUST QUALITY DETERIORATION>, “FUEL INJECTION SYSTEM”

NCEC0033S03

SEF392S

*1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame

data will not be displayed any longer after vehicle is driven 80 times (pattern C) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: The 1st trip DTC and the 1st trip

EC-64

freeze frame data will be cleared at the moment OK is detected. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. *8: 1st trip DTC will be cleared when vehicle is driven once (pattern C) without the same malfunction after DTC is stored in ECM.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” Driving Pattern B

NCEC0033S04 NCEC0033S0401

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunction. I The MI will go off when the B counter reaches 3. (*2 in EC-SR-64)

Driving Pattern C

NCEC0033S0402

Driving pattern C means the vehicle operation as follows: 1) The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) × (1±0.1) [%] Engine coolant temperature (T) condition: I When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). I When the freeze frame data shows higher than or equal to 70°C (158°F), “T” should be higher than or equal to 70°C (158°F). Example: If the stored freeze frame data is as follows: Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F) To be satisfied with driving pattern C, the vehicle should run under the following conditions: Engine speed: 475 - 1,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more than 70°C (158°F) I The C counter will be cleared when the malfunction is detected regardless of driving pattern C. I The C counter will be counted up when driving pattern C is satisfied without the same malfunction. I The DTC will not be displayed after C counter reaches 80. I The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM.

EC-65

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

OBD System Operation Chart (Cont’d)

RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S05

SEF393S

*1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM.

*4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 40 times (pattern A) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC

EC-66

and the 1st trip freeze frame data will be stored in ECM. *6: 1st trip DTC will be cleared after vehicle is driven once (pattern B) without the same malfunction. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

OBD System Operation Chart (Cont’d)

EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION SYSTEM” NCEC0033S06 Driving Pattern A NCEC0033S0601

AEC574

I I I

The A counter will be cleared when the malfunction is detected regardless of (1) - (4). The A counter will be counted up when (1) - (4) are satisfied without the same malfunction. The DTC will not be displayed after the A counter reaches 40.

Driving Pattern B

NCEC0033S0602

Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. I The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. I The B counter will be counted up when driving pattern B is satisfied without any malfunctions. I The MI will go off when the B counter reaches 3 (*2 in EC-SR-66).

EC-67

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

CONSULT-II

CONSULT-II Fuel pump fuse

CONSULT-II INSPECTION PROCEDURE

=NCEC0034 NCEC0034S01

1. 2.

Turn ignition switch OFF. Connect “CONSULT-II” to data link connector. (Data link connector is located behind the fuse box cover.)

3. 4.

Turn ignition switch ON. Touch “START”.

5.

Touch “ENGINE”.

Fuel pump relay

Data link connector

SEF192X

PBR455D

PEF895K

6.

Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

PEF216U

EC-68

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II (Cont’d)

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NCEC0034S02 DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS

ENGINE CONTROL COMPONENT PARTS

Item

INPUT

WORK SUPPORT

DATA MONITOR

DATA MONITOR (SPEC)

X

X

X

X

X

X

DTC CONFIRMATION ACTIVE TEST

SRT STATUS

DTC WORK SUPPORT

DTC*1

FREEZE FRAME DATA*2

Camshaft position sensor

X

X

Mass air flow sensor

X

Engine coolant temperature sensor

X

Heated oxygen sensor 1 (front)

X

X

X

X

X

Heated oxygen sensor 2 (rear)

X

X

X

X

X

Vehicle speed sensor or ABS actuator and electric unit (control unit)

X

X

X

Throttle position sensor

X

X

X

Intake air temperature sensor

X

X

X

Crankshaft position sensor (OBD)

X

X

X

Knock sensor

X X

X

X

X

Closed throttle position switch (throttle position sensor signal)

X

X

Air conditioner switch

X

X

Refrigerant pressure sensor

X

X

X

X

Power steering oil pressure switch

X

X

Battery voltage

X

X

Electrical load

X

X

Ignition switch (start signal) Closed throttle position switch

Park/Neutral position (PNP) switch

X

X

EC-69

X

X

X

X

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS WORK SUPPORT

Item

DTC*1

FREEZE FRAME DATA*2

ENGINE CONTROL COMPONENT PARTS

Injectors

DATA MONITOR

DATA MONITOR (SPEC)

ACTIVE TEST

X

X

X

Power transistor (Ignition timing)

X

X (Ignition signal)

X

X

X

IACV-AAC valve

X

X

X

X

X

X

X

X

X

X

X

X

X

EVAP canister purge volume control solenoid valve OUTPUT

DTC CONFIRMATION

Air conditioner relay Fuel pump relay

X

SRT STATUS

X

Heated oxygen sensor 1 (front) heater

X

X

X

X

Heated oxygen sensor 2 (rear) heater

X

X

X

X

Cooling fan

X

X

X

X

X

Calculated load value

X

DTC WORK SUPPORT

X

X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-SR-50.

FUNCTION Diagnostic test mode

NCEC0034S03

Function

Work support

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

Self-diagnostic results

Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.*1

Data monitor

Input/Output data in the ECM can be read.

Data monitor (spec)

Input/Output specifications of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read.

Active test

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

DTC confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

ECM part number

ECM part numbers can be read.

*1 The following emission-related diagnostic information is cleared when the ECM memory is erased. 1) Diagnostic trouble codes 2) 1st trip diagnostic trouble codes 3) Freeze frame data 4) 1st trip freeze frame data 5) System readiness test (SRT) codes 6) Test values 7) Distance traveled while MI is activated 8) Others

EC-70

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II (Cont’d)

WORK SUPPORT MODE WORK ITEM

NCEC0034S04

CONDITION

USAGE

IGNITION TIMING ADJ

I IGNITION TIMING FEEDBACK CONTROL WILL BE HELD BY TOUCHING “START”. AFTER DOING SO, ADJUST IGNITION TIMING WITH A TIMING LIGHT BY TURNING THE CAMSHAFT POSITION SENSOR.

When adjusting initial ignition timing

FUEL PRESSURE RELEASE

I FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS.

When releasing fuel pressure from fuel line

TARGET IDLE RPM ADJ

I IDLE CONDITION

When setting target idle speed

TARGET IGNITION TIMING ADJ

I IDLE CONDITION

When adjusting target ignition timing After adjustment, confirm target ignition timing with a timing light.

SELF DIAGNOSTIC MODE DTC and 1st Trip DTC

NCEC0034S05 NCEC0034S0501

Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX”, EC-SR-6.

Freeze Frame Data and 1st Trip Freeze Frame Data NCEC0034S0502 Freeze frame data item*

Description

DIAG TROUBLE CODE [PXXXX]

I Engine Control component part/control system has a trouble code, it is displayed as “PXXXX”. [Refer to “Alphabetical & P No. Index for DTC” (EC-SR-6).]

FUEL SYS DATA

I “Fuel injection system status” at the moment a malfunction is detected is displayed. I One mode in the following is displayed. “MODE 2”: Open loop due to detected system malfunction “MODE 3”: Open loop due to driving conditions (power enrichment, deceleration enrichment) “MODE 4”: Closed loop - using oxygen sensor(s) as feedback for fuel control “MODE 5”: Open loop - has not yet satisfied condition to go to closed loop

CAL/LD VALUE [%]

I The calculated load value at the moment a malfunction is detected is displayed.

COOLANT TEMP [°C] or [°F]

I The engine coolant temperature at the moment a malfunction is detected is displayed.

S-FUEL TRIM [%]

I “Short-term fuel trim” at the moment a malfunction is detected is displayed. I The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule.

L-FUEL TRIM [%]

I “Long-term fuel trim” at the moment a malfunction is detected is displayed. I The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim.

ENGINE SPEED [rpm] I The engine speed at the moment a malfunction is detected is displayed. VHCL SPEED [km/h] or [mph]

I The vehicle speed at the moment a malfunction is detected is displayed.

*: The items are the same as those of 1st trip freeze frame data.

EC-71

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

CONSULT-II (Cont’d)

DATA MONITOR MODE Monitored item [Unit]

ECM input signals

NCEC0034S06

Main signals

Description

Remarks I Accuracy becomes poor if engine speed drops below the idle rpm. I If the signal is interrupted while the engine is running, an abnormal value may be indicated.

ENG SPEED [rpm]

q

q

I Indicates the engine speed computed from the REF signal (180° signal) of the camshaft position sensor.

MAS A/F SE-B1 [V]

q

q

I The signal voltage of the mass air flow sensor is displayed.

I When the engine is stopped, a certain value is indicated. I When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed.

COOLAN TEMP/S [°C] or [°F]

q

q

I The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

HO2S1 (B1) [V]

q

q

I The signal voltage of the heated oxygen sensor 1 (front) is displayed.

HO2S2 (B1) [V]

q

I The signal voltage of the heated oxygen sensor 2 (rear) is displayed.

q

I Display of heated oxygen sensor 1 (front) signal during air-fuel ratio feedback control: RICH ... means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN ... means the mixture became “lean”, and control is being affected toward a rich mixture.

HO2S2 MNTR (B1) [RICH/LEAN]

q

I Display of heated oxygen sensor 2 (rear) signal: RICH ... means the amount of oxygen I When the engine is stopped, a cerafter three way catalyst is relatively tain value is indicated. small. LEAN ... means the amount of oxygen after three way catalyst is relatively large.

VHCL SPEED SE [km/h] or [mph]

q

BATTERY VOLT [V]

q

THRTL POS SEN [V]

q

INT/A TEMP SE [°C] or [°F]

q

START SIGNAL [ON/OFF]

q

HO2S1 MNTR (B1) [RICH/LEAN]

q

I The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed. I The power supply voltage of ECM is displayed.

q

I The throttle position sensor signal voltage is displayed. I The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated.

q

I Indicates [ON/OFF] condition from the starter signal. I Indicates mechanical contact [ON/OFF] condition of the closed throttle position switch.

CLSD THL/P SW [ON/OFF] CLSD THL POS [ON/OFF]

q

I After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. I When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously.

q

I Indicates idle position [ON/OFF] computed by ECM according to the throttle position sensor signal.

EC-72

I After starting the engine, [OFF] is displayed regardless of the starter signal.

SR20DE

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II (Cont’d) ECM input signals

Main signals

AIR COND SIG [ON/OFF]

q

q

I Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioning signal.

P/N POSI SW [ON/OFF]

q

q

I Indicates [ON/OFF] condition from the PNP switch signal.

q

I Indicates [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure switch signal.

q

I Indicates [ON/OFF] condition from the electrical load signal and/or lighting switch. ON ... rear defogger is operating and/or lighting switch is on. OFF ... rear defogger is not operating and lighting switch is not on.

Monitored item [Unit]

PW/ST SIGNAL [ON/OFF]

q

Description

LOAD SIGNAL [ON/OFF]

q

IGNITION SW [ON/OFF]

q

I Indicates [ON/OFF] condition from ignition switch.

HEATER FAN SW [ON/OFF]

q

I Indicates [ON/OFF] condition from the heater fan switch.

INJ PULSE -B1 [msec]

q

I Indicates the actual fuel injection pulse I When the engine is stopped, a cerwidth compensated by ECM according to tain computed value is indicated. the input signals. I “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction.

B/FUEL SCHDL [msec]

IGN TIMING [BTDC]

q

I Indicates the ignition timing computed by ECM according to the input signals.

IACV-AAC/V [step]

q

I Indicates the IACV-AAC valve control value computed by ECM according to the input signals.

A/F ALPHA -B1 [%]

q

I Indicates the mean value of the air-fuel ratio feedback correction factor per cycle.

AIR COND RLY [ON/OFF]

q

I Indicates the air conditioner relay control condition determined by ECM according to the input signals.

FUEL PUMP RLY [ON/OFF]

q

I Indicates the fuel pump relay control condition determined by ECM according to the input signals.

q

I Indicates the control condition of the cooling fan determined by ECM according to the input signals. HI ... High speed operation LOW ... Low speed operation OFF ... Stop

COOLING FAN [HI/LOW/OFF]

HO2S1 HTR (B1) [ON/OFF]

Remarks

I Indicates [ON/OFF] condition of heated oxygen sensor 1 (front) heater determined by ECM according to the input signals.

EC-73

I When the engine is stopped, a certain value is indicated. I This data also includes the data for the air-fuel ratio learning control.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

CONSULT-II (Cont’d)

Monitored item [Unit]

ECM input signals

Main signals

Description

HO2S2 HTR (B1) [ON/OFF]

I Indicates [ON/OFF] condition of heated oxygen sensor 2 (rear) heater determined by ECM according to the input signals.

PURG VOL C/V [%]

I Indicates the EVAP canister purge volume control solenoid valve computed by the ECM according to the input signals. I The opening becomes larger as the value increases.

CAL/LD VALUE [%]

I “Calculated load value” indicates the value of the current airflow divided by peak airflow.

ABSOL TH⋅P/S [%]

I “Absolute throttle position sensor” indicates the throttle opening computed by ECM according to the signal voltage of the throttle position sensor.

MASS AIRFLOW [gm/s]

I Indicates the mass airflow computed by ECM according to the signal voltage of the mass air flow sensor.

IDL A/V LEAN

I Display the condition of idle air volume learning YET...Idle air volume learning has not been performed yet. CMPLT...Idle air volume learning has already been performed successfully. INCMP...Idle air volume learning has not been performed successfully.

TRVL AFTER MIL [km] or [Mile]

I Distance traveled while MI is activated

VOLTAGE [V]

I Voltage measured by the voltage probe.

I Pulse width, frequency or duty cycle measured by the pulse probe.

PULSE [msec] or [Hz] or [%]

Remarks

I Only “#” is displayed if item is unable to be measured. I Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured.

DATA MONITOR (SPEC) MODE Monitored item [Unit]

MAS A/F SE-B1 [V]

ECM input signals

Main signals

q

q

Description

NLEC1365S07

Remarks

I The signal voltage of the mass air flow sen- I When the engine is running, specifisor specification is displayed. cation range is indicated.

B/FUEL SCHDL [msec]

I “Base fuel schedule” indicates the fuel injecI When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction.

A/F ALPHA-B1 [%]

I When the engine is running, specifiI Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. I This data also includes the data for the air-fuel ratio learning control.

q

NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-74

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE CONSULT-II (Cont’d)

ACTIVE TEST MODE TEST ITEM

CONDITION

NCEC0034S07

JUDGEMENT

CHECK ITEM (REMEDY)

FUEL INJECTION

I Engine: Return to the original trouble condition If trouble symptom disappears, see I Change the amount of fuel injec- CHECK ITEM. tion using CONSULT-II.

I Harness and connector I Fuel injectors I Heated oxygen sensor 1 (front)

IACV-AAC/V OPENING

I Engine: After warming up, idle the engine. I Change the IACV-AAC valve opening steps using CONSULTII.

Engine speed changes according to the opening steps.

I Harness and connector I IACV-AAC valve

ENG COOLANT TEMP

I Engine: Return to the original trouble condition I Change the engine coolant temperature indication using CONSULT-II.

If trouble symptom disappears, see CHECK ITEM.

I Harness and connector I Engine coolant temperature sensor I Fuel injectors

IGNITION TIMING

I Engine: Return to the original trouble condition I Timing light: Set I Retard the ignition timing using CONSULT-II.

If trouble symptom disappears, see CHECK ITEM.

I Adjust initial ignition timing

POWER BALANCE

I Engine: After warming up, idle the engine. I Air conditioner switch “OFF” I Shift lever “N” I Cut off each injector signal one at a time using CONSULT-II.

Engine runs rough or dies.

I I I I I I

COOLING FAN

I Ignition switch: ON I Turn the cooling fan “ON” and “OFF” using CONSULT-II.

Cooling fan moves and stops.

I Harness and connector I Cooling fan motor

FUEL PUMP RELAY

I Ignition switch: ON (Engine stopped) I Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound.

Fuel pump relay makes the operating sound.

I Harness and connector I Fuel pump relay

Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils

SELF-LEARNING I In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching CONT “CLEAR” on the screen.

PURG VOL CONT/V

I Engine: After warming up, idle the engine. I Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II.

IDLE AIR VOL LEARN

I In this test, the idle air volume that keeps the engine within the specified range is memorized in ECM.

DTC CONFIRMATION MODE SRT STATUS Mode

I Harness and connector I EVAP canister purge volume control solenoid valve

NCEC0034S08 NCEC0034S0801

For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-SR-49.

SRT Work Support Mode This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.

EC-75

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

CONSULT-II (Cont’d)

DTC Work Support Mode TEST MODE

Heated oxygen sensor 1 (front)

TEST ITEM

CONDITION

REFERENCE PAGE

HO2S1 (B1) P0130

EC-SR-144

HO2S1 (B1) P0131

EC-SR-150

HO2S1 (B1) P0132

Refer to corresponding trouble diagnosis for DTC.

HO2S1 (B1) P0133 HO2S2 (B1) P0137 Heated oxygen sensor 2 (rear)

NCEC0034S0802

EC-SR-156 EC-SR-162 EC-SR-180

HO2S2 (B1) P0138

EC-SR-187

HO2S2 (B1) P0139

EC-SR-194

REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NCEC0034S10

SEF705Y

SEF707X

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): I The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC 1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data...xx%” as shown at left, and the data after the malfunction detection is recorded. Then when the percentage reached is 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data...xx%”, “REALTIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): I DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. Use these triggers as follows: 1) “AUTO TRIG” I While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. I While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent.

EC-76

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE CONSULT-II (Cont’d)

2) I

When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.) “MANU TRIG” If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

SEF720X

EC-77

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Generic Scan Tool (GST)

Generic Scan Tool (GST) DESCRIPTION

NCEC0035 NCEC0035S01

Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4 ISO 15031-4 has 9 different functions explained on the next page. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual.

SEF139P

GST INSPECTION PROCEDURE Fuel pump fuse

1. 2.

NCEC0035S02

Turn ignition switch OFF. Connect “GST” to data link connector. (Data link connector is located under the fuse box cover.)

Fuel pump relay

Data link connector

SEF192X

3. 4.

Turn ignition switch ON. Enter the program according to instruction on the screen or in the operation manual. (*: Regarding GST screens in this section, sample screens are shown.)

SEF398S

5.

Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker.

SEF416S

EC-78

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

SR20DE

Generic Scan Tool (GST) (Cont’d)

FUNCTION Diagnostic test mode

NCEC0035S03

Function

MODE 1

READINESS TESTS

This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, distance traveled while MI is activated and system status information.

MODE 2

(FREEZE DATA)

This mode gains access to emission-related data value which were stored by ECM during the freeze frame. [For details, refer to “Freeze Frame Data” (EC-SR-68).]

MODE 3

DTCs

This mode gains access to emission-related power train trouble codes which were stored by ECM.

MODE 4

CLEAR DIAG INFO

This mode can clear all emission-related diagnostic information. This includes: I Clear number of diagnostic trouble codes (MODE 1) I Clear diagnostic trouble codes (MODE 3) I Clear trouble code for freeze frame data (MODE 1) I Clear freeze frame data (MODE 2) I Reset status of system monitoring test (MODE 1) I Clear on board monitoring test results (MODE 6 and 7)

MODE 6

(ON BOARD TESTS)

This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored.

MODE 7

(ON BOARD TESTS)

This mode enables the off board test drive to obtain test results for emission-related powertrain components/systems that are continuously monitored during normal driving conditions.

MODE 8 MODE 9

— (CALIBRATION ID)

This mode is not applicable on this vehicle. This mode enables the off-board (External test equipment) to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs.

EC-79

TROUBLE DIAGNOSIS — INTRODUCTION

SR20DE

Introduction

Introduction

MEF036D

SEF233G

NCEC0036

The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow” on EC-SR-82. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle.

SEF234G

DIAGNOSTIC WORKSHEET KEY POINTS WHAT ..... WHEN ..... WHERE ..... HOW .....

Vehicle & engine model Date, Frequencies Road conditions Operating conditions, Weather conditions, Symptoms SEF907L

NCEC0036S01

There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. Some conditions may cause the malfunction indicator to come on steady or blink and DTC to be detected. Example: Vehicle ran out of fuel, which caused the engine to misfire.

EC-80

TROUBLE DIAGNOSIS — INTRODUCTION

SR20DE Introduction (Cont’d)

Worksheet Sample

NCEC0036S0101

MTBL0311

EC-81

TROUBLE DIAGNOSIS — INTRODUCTION

SR20DE

Work Flow

Work Flow

NCEC0037

SEF510ZD

*1: If the incident cannot be duplicated, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-SR-115.

*3: If time data of “SELF-DIAG RESULTS” is other than “0” or “1t” refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *4: If the malfunctioning part cannot

EC-82

be found, refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. *5: EC-SR-93 *6: EC-SR-52 *7: EC-SR-110

TROUBLE DIAGNOSIS — INTRODUCTION

SR20DE Work Flow (Cont’d)

DESCRIPTION FOR WORK FLOW STEP

NCEC0037S01

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-SR-82.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II or Generic Scan Tool) the (1st trip) Diagnostic Trouble Code (DTC) and the (1st trip) freeze frame data, then erase the code and the data. (Refer to EC-SR-49.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. See EC-SR-94.) Also check related service bulletins for information.

STEP III

Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the (1st trip) Diagnostic Trouble Code by driving in (or performing) the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or Generic Scan Tool. During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.) In case the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the (1st trip) DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX. If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-SR-84.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS-SPECIFICATION VALUE”. (Refer to EC-SR-110.) (If malfunction is detected, proceed to “REPAIR/ REPLACE”). Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-SR-94.)

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-SR-103. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”). Repair or replace the malfunction parts.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” and confirm the normal code [Diagnostic trouble code No. P0000 or 0000] is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in ECM. (Refer to EC-SR-49.)

EC-83

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE

Basic Inspection

Basic Inspection

NCEC0038

Precaution: Perform Basic Inspection without electrical or mechanical loads applied; I Headlamp switch is OFF, I On vehicles equipped with daytime running light systems, set lighting switch to the 1st position to light only small lamps. I Air conditioner switch is OFF, I Rear window defogger switch is OFF, I Steering wheel is in the straight-ahead position, etc. 1

INSPECTION START

1. Check service records for any recent repairs that may indicate a related problem, or the current need for scheduled maintenance. 2. Open engine hood and check the following: I Harness connectors for improper connections I Vacuum hoses for splits, kinks, or improper connections I Wiring for improper connections, pinches, or cuts I Air cleaner clogging I Hoses and ducts for leaks

SEF983U

©

2

GO TO 2.

CHECK THROTTLE DRUM OPERATION

Confirm that throttle drum is in contact with stopper. OK or NG OK (With CONSULT-II)

©

GO TO 5.

OK (Without CONSULT-II)

©

GO TO 8.

NG

©

GO TO 3.

3

CHECK ACCELERATOR WIRE INSTALLATION

Check accelerator wire for slack. OK or NG OK

©

GO TO 4.

NG

©

Adjust accelerator wire. Refer to FE-section, “Adjusting Accelerator Wire”.

4

CHECK THROTTLE VALVE OPERATION

1. Remove intake air ducts. 2. Check throttle valve operation when moving throttle drum by hand. OK or NG OK

©

Retighten the throttle drum fixing nuts.

NG

©

Clean the throttle body and throttle valve.

EC-84

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE Basic Inspection (Cont’d)

5 1. 2. 3. 4. 5.

CHECK THROTTLE POSITION SENSOR IDLE POSITION With CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Select ”THRTL POS SEN” and “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. Make sure that “THRTL POS SEN” indicates 0.35 to 0.65 V, and “CLSD THL POS” indicates “ON”. (Accelerator pedal is fully released.)

NEF238A

OK or NG OK

©

GO TO 11.

NG

©

GO TO 6.

6

ADJUSTMENT THROTTLE POSITION SENSOR IDLE POSITION

With CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until “THRTL POS SEN” indication becomes 0.35 to 0.65 V.

SEF964W

3. Tighten the throttle position sensor fixing bolts. ©

GO TO 7.

EC-85

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE

Basic Inspection (Cont’d)

7

RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY

With CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cold, the throttle position sensor idle position memory will not reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Select “CLSD THL POS” in “DATA MONITOR” mode with CONSULT-II. 3. Stop engine. (Turn ignition switch “OFF”.) 4. Turn ignition switch “ON” and wait at least 5 seconds.

or

SEF864V

5. Turn ignition switch “OFF” and wait at least 5 seconds. 6. Repeat steps 4 and 6 until “CLSD THL POS” indication changes to “ON”.

SEF061Y

©

8 1. 2. 3. 4.

GO TO 11.

CHECK THROTTLE POSITION SENSOR IDLE POSITION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Turn ignition switch “ON”. Check voltage between ECM terminal 92 and ground with accelerator pedal fully released.

NEF239A

Voltage: 0.35 to 0.65V OK or NG OK

©

GO TO 6.

NG

©

GO TO 9.

EC-86

SR20DE

TROUBLE DIAGNOSIS — BASIC INSPECTION

Basic Inspection (Cont’d)

9

ADJUST THROTTLE POSITION SENSOR IDLE POSITION

Without CONSULT-II 1. Loosen throttle position sensor fixing bolts. 2. Turn throttle position sensor body clockwise or counterclockwise until the voltage between ECM terminal 92 and ground becomes 0.35 to 0.65 V.

SEF964W

3. Tighten the throttle position sensor fixing bolts. ©

10

GO TO 10.

RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY

Without CONSULT-II NOTE: Always warm up engine to normal operating temperature. If engine is cold, the throttle position sensor idle position memory will not reset correctly. 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. (Turn ignition switch “OFF”.) 3. Turn ignition switch “ON” and wait at least 5 seconds.

SEF864V

4. Turn ignition switch “OFF” and wait at least 9 seconds. 5. Repeat steps 4 and 6, 20 times. ©

11

GO TO 11.

CHECK (1ST TRIP) DTC

1. Start engine and warm it up to normal operating temperature. 2. Rev (2,000 to 3,000 rpm) two or three times. 3. Make sure no (1st trip) DTC is displayed with CONSULT-II, GST or Diagnostic Test Mode II (Self-diagnostic Result). OK or NG OK

©

GO TO 13.

NG

©

GO TO 12.

EC-87

TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d)

12

REPAIR MALFUNCTION

Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. ©

13

GO TO 11.

CHECK TARGET IDLE SPEED

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK

©

GO TO 22.

NG

©

GO TO 14.

14

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 15.

INCMP

©

1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.

15

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK

©

GO TO 20.

NG

©

GO TO 16.

16

REPLACE IACV-AAC VALVE

Replace IACV-AAC valve. ©

17

GO TO 17.

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 18.

INCMP

©

1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 14.

EC-88

SR20DE

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE Basic Inspection (Cont’d)

18

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK

©

GO TO 20.

NG

©

GO TO 19.

19

CHECK ECM FUNCTION

1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-SR58. ©

20

GO TO 14.

CHECK IGNITION TIMING

1. Start engine and warm it up to normal operating temperature. 2. Check ignition timing at idle using a timing light. Timing light

SEF984U

Ignition timing: 15°±2° BTDC OK or NG OK

©

GO TO 28.

NG

©

GO TO 21.

21

CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM-section. OK or NG OK

©

GO TO 19.

NG

©

1. Repair the timing chain installation. 2. GO TO 14.

EC-89

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE

Basic Inspection (Cont’d)

22

CHECK IGNITION TIMING

1. Start engine and let it idle. 2. Check ignition timing at idle using a timing light.

Timing light

SEF984U

Ignition timing: 15°±2° BTDC OK or NG OK

©

GO TO 28.

NG

©

GO TO 23.

23

PERFORM IDLE AIR VOLUME LEARNING

Refer to “Idle Air Volume Learning”, EC-SR-46 Which is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

GO TO 24.

INCMP

©

GO TO 23.

24

CHECK TARGET IDLE SPEED AGAIN

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “ENG SPEED” in “DATA MONITOR” mode with CONSULT-II. 3. Check idle speed. 750±50 rpm Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. 750±50 rpm OK or NG OK

©

GO TO 26.

NG

©

GO TO 15.

25

CHECK ECM FUNCTION

1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of a problem, but this is rarely the case.) 2. Perform initialization of NATS system and registration of NATS ignition key IDs. Refer to “NATS (Nissan Anti-Theft System)”, EC-SR-58. ©

26

GO TO 23.

CHECK IGNITION TIMING AGAIN

Check ignition timing again. Refer to Test No. 22. OK or NG OK

©

GO TO 28.

NG

©

GO TO 27.

EC-90

TROUBLE DIAGNOSIS — BASIC INSPECTION

SR20DE Basic Inspection (Cont’d)

27

CHECK TIMING CHAIN INSTALLATION

Check timing chain installation. Refer to EM-section. OK or NG OK

©

GO TO 25.

NG

©

1. Repair the timing chain installation. 2. GO TO 23.

28

ERASE UNNECESSARY DTC

After this inspection, unnecessary DTC No. might be displayed. Erase the stored memory in ECM. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. ©

INSPECTION END

EC-91

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

DTC Inspection Priority Chart

DTC Inspection Priority Chart

NCEC0039

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority

Detected items (DTC)

1

I I I I I I I I I I I

P0100 Mass air flow sensor P0110 Intake air temperature sensor P0115 Engine coolant temperature sensor P0120 Throttle position sensor P0325 Knock sensor P0340 Camshaft position sensor P0500 Vehicle speed sensor P0605 ECM P0335, P1336 Crankshaft position sensor (OBD) P1605 A/T diagnosis communication line P1706 Park/Neutral position switch

2

I I I I I I I I

P0130 P0135 P0137 P0141 P0443 P0510 P0705 P1217

3

I I I I I

P0171, P0172 Fuel injection system function P0300 - P0304 Misfire P0420 Three way catalyst function P0505 IACV-AAC valve P1778 CVT step motor function

- P0134 Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater - P0140 Heated oxygen sensor 2 (rear) Heated oxygen sensor 2 (rear) heater EVAP canister purge volume control solenoid valve Closed throttle position switch - P0725, P0740 - P1791 CVT related sensors, solenoid valves and switches Overheat (Cooling system)

EC-92

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Fail-safe Chart

Fail-safe Chart

NCEC0040

The ECM enters fail-safe mode if any of the following malfunctions is detected due to the open or short circuit. When the ECM enters the fail-safe mode, the MI illuminates. DTC No. CONSULT-II GST

ECM*1

P0100

0100

Mass air flow sensor circuit

P0115

0115

Engine coolant tempera- Engine coolant temperature will be determined by ECM based on the time ture sensor circuit after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. The radiator fan operates.

Detected items

Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

Condition Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or Start

80°C (176°F)

Except as shown above P0120

0120

Throttle position sensor circuit

When engine is idling When accelerating Unable to access Diagnostic Test Mode II

ECM

40 - 80°C (104 - 176°F) (Depends on the time)

Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor. Condition

Unable to access ECM

Engine coolant temperature decided (CONSULT-II display)

Driving condition Normal Poor acceleration

ECM fail-safe activating condition The computing function of the ECM was judged to be malfunctioning. When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in the CPU of ECM), the MI on the instrument panel lights to warn the driver. However it is not possible to access ECM and DTC cannot be confirmed. Engine control with fail-safe When ECM fail-safe is operating, fuel injection, ignition timing, fuel pump operation and IACV-AAC valve operation are controlled under certain limitations. ECM fail-safe operation Engine speed

Engine speed will not rise more than 3,000 rpm

Fuel injection

Simultaneous multiport fuel injection system

Ignition timing

Ignition timing is fixed at the preset valve

Fuel pump

Fuel pump relay is “ON” when engine is running and “OFF” when engine stalls

IACV-AAC valve

Full open

Replace ECM, if ECM fail-safe condition is confirmed. *: In Diagnostic Test Mode II (Self-diagnostic results)

EC-93

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart

Symptom Matrix Chart

NCEC0041

SYSTEM — ENGINE CONTROL SYSTEM

NCEC0041S01

Fuel

Fuel pump circuit

1

1

2

3

2

Fuel pressure regulator system

3

3

4

4

4

Injector circuit

1

1

2

3

2

Evaporative emission system

3

3

4

4

4

Positive crankcase ventilation system

3

3

4

4

4

Incorrect idle speed adjustment

3

3

IACV-AAC valve circuit

1

1

2

3

3

Incorrect ignition timing adjustment

3

3

1

1

Ignition circuit

1

1

2

Main power supply and ground circuit

2

2

Air conditioner circuit

2

2

Air

Ignition

EXCESSIVE FUEL CONSUMPTION

AL AM HA

2

2

4

4

2

2

4

4

4

4

4

1 2

EC-SR-316 EC-SR-32

2

EC-SR-32

4

4

EC-SR-27

4

4

4

1

1

1

1

2

2

2

2

1

1

1

1

EC-SR-34

2

2

2

2

2

EC-SR-306

3

3

3

3

3

3

3

3

3

3

EC-94

3

4

2

Reference page

4

1 - 6: The numbers refer to the order of inspection. (continued on next page)

4

3

BATTERY DEAD (UNDER CHARGE)

OVERHEATS/WATER TEMPERATURE HIGH AK

EXCESSIVE OIL CONSUMPTION

SLOW/NO RETURN TO IDLE AJ

ROUGH IDLE/HUNTING

AF AG AH

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

AA AB AC AD AE

IDLING VIBRATION

Warranty symptom code

ENGINE STALL

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

2 3

1

EC-SR-30 EC-SR-34 2

EC-SR-263

3

2

EC-SR-115

3

2

HA section

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Symptom Matrix Chart (Cont’d)

ROUGH IDLE/HUNTING

IDLING VIBRATION

SLOW/NO RETURN TO IDLE

OVERHEATS/WATER TEMPERATURE HIGH

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

BATTERY DEAD (UNDER CHARGE)

AK

AL

AM

HA

3

3

3

3

EC-SR239

2

2

2

2

2

EC-SR120

2

3

2

2

2

2

EC-SR144, 150

1

2

3

2

3

2

2

3

2

EC-SR132

Throttle position sensor circuit

1

2

2

2

2

2

2

2

EC-SR137

Incorrect throttle position sensor adjustment

3

1

1

1

1

1

1

1

EC-SR-84

Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit

2

3

3

3

EC-SR255

3

EC-SR230

3

EC-SR277, 93

LACK OF POWER/POOR ACCELERATION

AJ

SPARK KNOCK/DETONATION

AH

HESITATION/SURGING/FLAT SPOT

AG

ENGINE STALL

AF

HARD/NO START/RESTART (EXCP. HA)

HIGH IDLE/LOW IDLE

SYMPTOM

AA

AB

AC

AD

AE

Camshaft position sensor circuit

2

2

3

3

Mass air flow sensor circuit

1

1

2

1

Warranty symptom code

Heated oxygen sensor 1 (front) circuit Engine coolant temperature sensor circuit

1

Knock sensor circuit

2

ECM

2

Start signal circuit

2

2

3

3

3

3

3

3

3

EC-SR312

PNP switch circuit Power steering oil pressure switch circuit

3

Reference page

3

3

2

Electrical load signal circuit 1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-95

3

EC-SR298

3

3

3

3

EC-SR322

3

3

EC-SR326

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d)

SYSTEM — ENGINE MECHANICAL & OTHER

NCEC0041S03

Fuel

EXCESSIVE FUEL CONSUMPTION

AL AM HA

BATTERY DEAD (UNDER CHARGE)

OVERHEATS/WATER TEMPERATURE HIGH AK

EXCESSIVE OIL CONSUMPTION

SLOW/NO RETURN TO IDLE AJ

ROUGH IDLE/HUNTING

AF AG AH

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

AA AB AC AD AE

IDLING VIBRATION

Warranty symptom code

ENGINE STALL

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Fuel tank

Reference page

FE section 5

Fuel piping Vapor lock

5

5

5

5

5

5

5

5

5

5

5

5

5

Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air

5

—

Air duct Air cleaner Air leakage from air duct (Mass air flow sensor — throttle body) Throttle body, Throttle wire

5

5

5

5 5

5

5

5

5 5

FE section

Air leakage from intake manifold/ Collector/Gasket Cranking

—

Battery 1

1

1

1

1

1

1

Alternator circuit

EL section

Starter circuit

3

Flywheel

6

EM section

PNP switch

4

AT section

1

1 - 6: The numbers refer to the order of inspection. (continued on next page)

EC-96

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Symptom Matrix Chart (Cont’d)

Engine

EXCESSIVE FUEL CONSUMPTION

AL AM HA

BATTERY DEAD (UNDER CHARGE)

OVERHEATS/WATER TEMPERATURE HIGH AK

EXCESSIVE OIL CONSUMPTION

SLOW/NO RETURN TO IDLE AJ

ROUGH IDLE/HUNTING

AF AG AH

HIGH IDLE/LOW IDLE

LACK OF POWER/POOR ACCELERATION

SPARK KNOCK/DETONATION

HESITATION/SURGING/FLAT SPOT

AA AB AC AD AE

IDLING VIBRATION

Warranty symptom code

ENGINE STALL

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

Reference page

Cylinder head 5

5

5

5

5

5

5

5

Cylinder head gasket

4

3

Cylinder block Piston

4 EM section

Piston ring 6

6

6

6

6

6

6

6

5

5

5

5

5

5

5

5

Connecting rod Bearing Crankshaft Valve mechanism

Timing chain Camshaft EM section

Intake valve 3 Exhaust valve Exhaust

Exhaust manifold/Tube/Muffler/ Gasket

5

5

5

5

5

5

5

5

FE section

5

5

5

5

5

5

5

5

MA, EM and LC sections

Three way catalyst Lubrication

Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery Oil level (Low)/Filthy oil

Cooling

Radiator/Hose/Radiator filler cap Thermostat

5

LC section

Water pump Water gallery

5

5

5

5

Cooling fan

5

5

5

4 5

Coolant level (low)/Contaminated coolant

5 EC-SR-279 MA section

1 - 6: The numbers refer to the order of inspection.

EC-97

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0042

Remarks: I Specification data are reference values. I Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. (i.e., Adjust ignition timing with a timing light before monitoring IGN TIMING. Specification data might be displayed even when ignition timing is not adjusted to specification. This IGN TIMING monitors the data calculated by the ECM according to the input signals from the camshaft position sensor and other ignition timing related sensors.) I If the real-time diagnosis results are NG, and the on board diagnostic system results are OK, when diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal. MONITOR ITEM

CONDITION

ENG SPEED

I Tachometer: Connect I Run engine and compare tachometer indication with the CONSULT-II value.

MAS A/F SE -B1

I I I I

COOLAN TEMP/S

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

HO2S2 (B1) HO2S2 MNTR (B1)

Almost the same speed as the CONSULT-II value.

Idle

1.0 - 1.7V

2,500 rpm

1.5 - 2.4V

I Engine: After warming up

More than 70°C (158°F) 0 - 0.3V +, 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

SPECIFICATION

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

I Engine: After warming up

Revving engine from idle to 3,000 rpm quickly

0 - 0.3V +, 0.6 - 1.0V LEAN +, RICH

VHCL SPEED SE

I Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the CONSULT-II value

BATTERY VOLT

I Ignition switch: ON (Engine stopped)

11 - 14V

I Engine is idling

Throttle valve fully closed

0.35 - 0.65V

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

3.5 - 4.5V

THRTL POS SEN START SIGNAL

I Ignition switch: ON , START , ON

CLSD THL/P SW CLSD THL POS

I Engine: Idle

AIR COND SIG

I Engine: After warming up, idle the engine

P/N POSI SW

PW/ST SIGNAL

I Ignition switch: ON I Engine: After warming up, idle the engine

IGNITION SW

I Ignition switch: ON , OFF

INJ PULSE -B1

I I I I

HEATER FAN SW

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

I Ignition switch: ON

OFF , ON , OFF

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

A/C switch “OFF”

OFF

A/C switch “ON” (Compressor operates)

ON

Shift lever “P” or “N”

ON

Except above

OFF

Steering wheel in neutral position (forward direction)

OFF

The steering wheel is fully turned

ON ON , OFF

Idle

2.4 - 3.2 msec

2,000 rpm

1.9 - 2.8 msec

Heater fan switch: ON

ON

Heater fan switch: OFF

OFF

EC-98

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM LOAD SIGNAL

B/FUEL SCHDL

IGN TIMING

IACV-AAC/V

PURG VOL C/V

CONDITION I Engine: running

SPECIFICATION

Rear window defogger or headlamp “ON”

ON

Except the above

OFF

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.2 msec

2,000 rpm

1.4 - 2.8 msec

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

15° BTDC

2,000 rpm

Approx. 40° BTDC

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

5 - 20 steps

2,000 rpm

—

Vehicle stopped

0%

Vehicle running

—

Maintaining engine speed at 2,000 rpm

53 - 155%

I Engine: Running

A/F ALPHA -B1

I Engine: After warming up

AIR COND RLY

I Air conditioner switch: OFF , ON

OFF , ON ON

FUEL PUMP RLY

I Ignition switch is turned to ON (Operates for 2 seconds) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds) I Except as shown above

OFF Engine coolant temperature is 94°C (201°F) or less

COOLING FAN

I After warming up engine, idle the Engine coolant temperature is engine. between 95°C (203°F) and 104°C I Air conditioner switch: OFF (219°F). Engine coolant temperature is 105°C (221°F) or more

HO2S1 HTR (B1)

HO2S2 HTR (B1)

CAL/LD VALUE

ABSOL TH⋅P/S

MASS AIRFLOW

OFF

LOW

HIGH

I Engine speed: Below 3,200 rpm

ON

I More than 20 seconds after exceeding 3,200 rpm

OFF

I Engine speed: Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

I Engine speed: Above 3,600 rpm I Ignition switch ON (Engine stopped)

OFF

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

Not used

2,500 rpm

Not used

I Engine: Idle

Throttle valve fully closed

0.0°

I Ignition switch: ON (Engine stopped)

Throttle valve fully opened

Approx. 80°

Idle

2.5 - 5.0 g⋅m/s

2,500 rpm

7.1 - 12.5 g⋅m/s

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: N No-load

EC-99

SR20DE

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM

IDL A/V LEARN

TRVL AFTER MIL

CONDITION

I Ignition switch: ON

I Ignition switch: ON

SPECIFICATION

IDLE AIR VOL LEARN in ACTIVE TEST has not been performed

YET

IDLE AIR VOL LEARN in ACTIVE TEST has already been performed successfully

CMPLT

IDLE AIR VOL LEARN in ACTIVE TEST has not been performed successfully

INCMP

Vehicle has travelled after MI has turned ON.

0 - 65,535 km (0 - 40,722 mile)

Major Sensor Reference Graph in Data Monitor Mode

NCEC0043

The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)

THRTL POS SEN, ABSOL TH⋅P/S, CLSD THL POS

NCEC0043S01

Below is the data for “THRTL POS SEN”, “ABSOL TH⋅P/S” and “CLSD THL POS” when depressing the accelerator pedal with the ignition switch “ON”. The signal of “THRTL POS SEN” and “ABSOL TH⋅P/S” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. CLSD THL POS 10:22 OFF

-00"09 +02"69 ON

ABSOL TH P/S 10:22 % 0

25

50

-00"09 +02"69 75

100

THRTL POS SEN 10:22 x0.1V 0

13

26

-00"09 +02"69 38

51

Full Release

Full Depress SEF580W

ENG SPEED, MAS A/F SE -B1, THRTL POS SEN, HO2S2 (B1), HO2S1 (B1), INJ PULSE NCEC0043S02 -B1 Below is the data for “ENG SPEED”, “MAS A/F SE -B1”, “THRTL POS SEN”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE -B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine to normal operating temperature. Each value is for reference, the exact value may vary.

EC-100

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

● “ENG SPEED” should increase gradually while

.

ENG SPEED

depressing the accelerator pedal and should decrease gradually after releasing the pedal without any intermittent drop or rise.

● “MAS A/F SE -B1” should increase when

.

MAS A/F SE -B1

depressing the accelerator pedal and should decrease at the moment “THRTL POS SEN” is closed (accelerator pedal is released).

NEF066A

SEF601Y

EC-101

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

Major Sensor Reference Graph in Data Monitor Mode (Cont’d)

SEF170YA

EC-102

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value

ECM Terminals and Reference Value PREPARATION 1. 2.

NCEC0044 NCEC0044S01

ECM is located behind the center console. For this inspection: Remove the front passenger center console panel. Remove ECM harness protector.

SEF967W

3. I I I

Perform all voltage measurements with the connector connected. Extend tester probe as shown to perform tests easily. Open harness securing clip to make testing easier. Use extreme care not to touch 2 pins at one time. Data is for comparison and may not be exact.

SEF367I

ECM HARNESS CONNECTOR TERMINAL LAYOUTNCEC0044S02

SEF970W

ECM INSPECTION TABLE

NCEC0044S03

Specification data are reference values and are measured between each terminal and 48 (ECM ground).

EC-103

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

3

4

WIRE COLOR

W/R

L

ITEM

Heated oxygen sensor 2 (rear) heater

Heated oxygen sensor 1 (front) heater

CONDITION

DATA (DC Voltage)

[Engine is running] I Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

Approximately 0.7V

[Ignition switch “ON”] I Engine stopped I Engine speed is above 3,600 rpm

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Idle speed

Approximately 0V

[Engine is running] I More than 20 seconds after exceeding 3,200 rpm

BATTERY VOLTAGE (11 - 14V)

6 7 15 16

BR Y/B P OR

IACV-AAC valve

[Engine is running] I Warm-up condition I Idle speed

0 - 14V

10

R/W

CVT signal No. 3

[Engine is running] I Idle speed

0V

[Engine is running] I Cooling fan is not operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Cooling fan is operating

Approximately 0V

[Engine is running] I Warm-up condition I Idle speed

BATTERY VOLTAGE (11 - 14V)

13

LG/R

Cooling fan relay

5 - 12V 14

P/B

EVAP canister purge volume control solenoid valve (ON/OFF duty)

[Engine is running] I Warm-up condition I 2,000 rpm

SEF975W

19

21

22

23

L/R

B/P

OR/L

—

CVT signal No. 5

Fuel pump relay

Malfunction indicator

Air conditioner switch

[Engine is running] I Idle speed

Approximately 7.5V

[Ignition switch “ON”] I For 2 seconds after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”]

0 - 1V

[Engine is running] I Idle speed

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Both A/C switch and blower switch are “ON”

Approximately 0V

[Engine is running] I A/C switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

EC-104

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

31

WIRE COLOR

W/G

ITEM

ECM relay (Self shutoff)

CONDITION

DATA (DC Voltage)

[Engine is running] [Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”

0 - 1V

[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”

BATTERY VOLTAGE (11 - 14V) Approximately 10.5V

[Engine is running] I Warm-up condition I Idle speed

SEF973W

32

L/OR

Tachometer Approximately 10.5V

[Engine is running] I Engine speed is 2,000 rpm

SEF974W

Approximately 0.3V

[Engine is running] I Warm-up condition I Idle speed

SEF996V

35

W/L

Ignition signal

Approximately 0.8V

[Engine is running] I Engine speed is 2,000 rpm

SEF997V

EC-105

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 13V

[Engine is running] I Warm-up condition I Idle speed

SEF998V

36*1

G

Ignition check Approximately 12V

[Engine is running] I Engine speed is 2,000 rpm

SEF999V

40

41

42

43

44

46

Y

B/Y

G/OR

B/R

—

PU/W

Throttle position switch (Closed position)

[Engine is running] I Accelerator pedal released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”] I Accelerator pedal depressed

Approximately 0V

[Ignition switch “ON”]

Approximately 0V

[Ignition switch “START”]

9 - 12V

[Ignition switch “ON”] I Gear position is “Neutral position” (M/T models) I Gear position is “P” or “N” (CVT models)

Approximately 0V

[Ignition switch “ON”] I Except the above gear position

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “OFF”]

0V

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)

Approximately 0V

[Engine is running] I Air conditioner switch is “OFF”

Approximately 5V

[Engine is running] I Steering wheel is fully turned

Approximately 0V

[Engine is running] I Steering wheel is not turned

Approximately 5V

Start signal

PNP switch

Ignition switch

Air conditioner switch

Power steering oil pressure switch

48

B

ECM ground

[Engine is running] I Idle speed

Engine ground (Probe this terminal with (−) tester probe when measuring)

50

R

Electric load signal

[Engine is running] I Headlamp switch or rear window defogger switch is “ON”

BATTERY VOLTAGE (11 - 14V)

*1: If so equipped

EC-106

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

51

WIRE COLOR

LG/B

ITEM

Blower fan SW

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] I Blower fan switch is “ON”

Approximately 0V

[Ignition switch “ON”] I Blower fan switch is “OFF”

Approximately 5V

54

W/L

CVT signal No. 1

[Engine is running] I Idle speed

Approximately 0 - 3.5V

55

W/PU

CVT signal No. 2

[Engine is running] I Idle speed

Approximately 0 - 3.5V

56

LG/B

CVT signal No. 4

[Engine is running] I Idle speed I “R” position

0 - 3.5V

57

B

ECM ground

[Engine is running] I Idle speed

Engine ground

58

B

Sensors’ ground

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

[Engine is running] I Warm-up condition I Idle speed

1.3 - 1.7V

[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm

1.8 - 2.4V

61

B

Mass air flow sensor

0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF008W

63

L

Heated oxygen sensor 2 (rear)

[Engine is running] I After warming up to normal operating temperature and engine speed is 3,000 rpm

0 - Approximately 1.0V

64

G

Intake air temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with intake air temperature 3 - 5V (AC range)

[Engine is running] I Warm-up condition I Idle speed 0.2 ms

65

W

SEF721W

Crankshaft position sensor (OBD)

6 - 9V (AC range)

[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF722W

EC-107

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0.1 - 0.4V

[Engine is running] I Warm-up condition I Idle speed

66*2 75

L L

SEF006W

Camshaft position sensor (REF)

0.1 - 0.4V

[Engine is running] I Engine speed is 2,000 rpm

SEF007W

67

W/L

Power supply for ECM (Back-up)

[Ignition switch “OFF”]

BATTERY VOLTAGE (11 - 14V)

70

BR/Y

Engine coolant temperature sensor

[Engine is running]

Approximately 0 - 4.8V Output voltage varies with engine coolant temperature

— Y

[Engine is running] I Accelerator pedal released

0.35 - 0.65V

71 92

[Ignition switch “ON”] I Accelerator pedal fully depressed

Approximately 4V

Throttle position sensor

W

Mass air flow sensor ground

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

74

R/L

Refrigerant pressure sensor

[Engine is running] I Warm-up condition I Idle speed I Air conditioner is “ON”

More than 1.5V

81

W

Knock sensor

[Engine is running] I Idle speed

2.0 - 3.0V

73

Approximately 2.5V

[Engine is running] I Warm-up condition I Idle speed

SEF004W

85

B/W

Camshaft position sensor (Position signal)

Approximately 2.4V

[Engine is running] I Engine speed is 2,000 rpm

SEF005W

*2: Models before VIN - P11U0548750

EC-108

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 2.5V

86

OR/W

[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and elecI In 2nd gear position tric unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W

91

PU/Y

CVT check signal

[Engine is running] I Idle speed

0 - Approximately 5V

93*1

G/R

Data link connector

[Engine is running] ● Idle speed (CONSULT-II or GST is disconnected)

Approximately 0V BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Idle speed 101 103 105 107

R/B Y/B G/B L/B

Injector Injector Injector Injector

No. No. No. No.

1 2 3 4

SEF011W

BATTERY VOLTAGE (11 - 14V) [Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF012W

106 108

B/Y

ECM ground

[Engine is running] I Idle speed

0V

110 112

R R

Power supply for ECM

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

111

G

Sensors’ power supply

[Ignition switch “ON”]

Approximately 5V

G/W

Adjust switch

[Engine is running] I Idle speed

0V

BR/W

Data link connector

[Engine is running] I Idle speed (CONSULT-II or GST is disconnected)

0 - 10V

Refer to EL section

Immobilizer

[Engine is running] I Idle speed

BATTERY VOLTAGE (11 - 14V)

114*1

115

116

*1: If so equipped

EC-109

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

SR20DE

Description

Description

NLEC1748

The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the MIL. The SP value will be displayed for the following three items: I B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) I A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) I MAS A/F SE-B1 (The signal voltage of the mass air flow sensor)

Testing Condition

NLEC1749

I Vehicle driven distance: More than 5,000 km (3,107 miles) I Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2, 14.25 - 15.12 psi) I Atmospheric temperature: 20 - 30°C (68 - 86°F) I Engine coolant temperature: 75 - 95°C (167 - 203°F) I Transmission: Warmed-up*1 I Electrical load: Not applied*2 I Engine speed: Idle *1: For after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (CVT fluid temperature sensor signal) indicates less than 0.9V. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Cooling fans are not operating. Steering wheel is straight ahead.

Inspection Procedure

SEF601Z

NLEC1750

NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-84. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to “Diagnostic Procedure”, EC-111.

EC-110

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

SR20DE Diagnostic Procedure

Diagnostic Procedure

NLEC1751

SEF613ZA

EC-111

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

SR20DE

Diagnostic Procedure (Cont’d)

SEF768Z

EC-112

TROUBLE DIAGNOSIS — SPECIFICATION VALUE

SR20DE

Diagnostic Procedure (Cont’d)

SEF615Z

EC-113

TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT

SR20DE

Description

Description

NCEC0045

Intermittent incidents (I/I) may occur. In many cases, the problem resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer’s complaint often do not recur on DTC (1st trip) visits. Realize also that the most frequent cause of I/I occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the specific problem area.

COMMON I/I REPORT SITUATIONS

NCEC0045S01

STEP in Work Flow

Situation

II

The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “1t”.

III

The symptom described by the customer does not recur.

IV

(1st trip) DTC data does not appear during the DTC CONFIRMATION PROCEDURE.

VI

The TROUBLE DIAGNOSIS for PXXXX does not indicate the problem area.

Diagnostic Procedure 1

INSPECTION START

Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION-RELATED INFORMATION” (EC-SR-56).

©

2

GO TO 2.

CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection. Refer to “Circuit Inspection”, “GROUND INSPECTION” in GI section. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

3

SEARCH FOR ELECTRICAL INCIDENT

Perform “Incident Simulation Tests” in GI section. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK CONNECTOR TERMINALS

Refer to “How to Check Enlarged Contact Spring of Terminal” in GI section. OK or NG OK

©

INSPECTION END

NG

©

Repair or replace connector.

EC-114

NCEC0046

SR20DE

TROUBLE DIAGNOSIS FOR POWER SUPPLY

Main Power Supply and Ground Circuit

Main Power Supply and Ground Circuit WIRING DIAGRAM

NCEC0047

BATTERY

Refer to EL-POWER.

ST

OFF

ECM RELAY

ACC

IGNITION SWITCH

ON

FUSE BLOCK (J/B)

To EC-IBN/SG, EC-TP/SW, EC-AAC/V, EC-EGR

ECM

★ 1 :

C

17

M

23

: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models

.

REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) E103 FUSE BLOCK Junction Box (J/B)

YEC828

EC-115

SR20DE

TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d)

ECM TERMINALS AND REFERENCE VALUE

NCEC0048

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

31

WIRE COLOR

W/G

43

ITEM

CONDITION

ECM relay (Self shut-off)

B/R

DATA (DC Voltage)

[Engine is running] [Ignition switch “OFF”] I For 9 seconds after turning ignition switch “OFF”

0 - 1V

[Ignition switch “OFF”] I 9 seconds passed after turning ignition switch “OFF”

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “OFF”]

0V

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V) Engine ground (Probe this terminal with (−) tester probe when measuring)

Ignition switch

48

B

ECM ground

[Engine is running] I Idle speed

57

B

ECM ground

[Engine is running] I Idle speed

Engine ground

67

W/L

Power supply for ECM (Back-up)

[Ignition switch “OFF”]

BATTERY VOLTAGE (11 - 14V)

106 108

B/Y B/Y

ECM ground

[Engine is running] I Idle speed

Engine ground

110 112

R R

Power supply for ECM

[Ignition switch “ON”]

BATTERY VOLTAGE (11 - 14V)

DIAGNOSTIC PROCEDURE 1

NCEC0049

INSPECTION START

Start engine. Is engine running? Yes or No Yes

©

GO TO 4.

No

©

GO TO 2.

2

CHECK POWER SUPPLY-I

1. Turn ignition switch “OFF” and then “ON”. 2. Check voltage between ECM terminal 43 and ground with CONSULT-II or tester.

SEF981W

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-116

TROUBLE DIAGNOSIS FOR POWER SUPPLY

SR20DE

Main Power Supply and Ground Circuit (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. I Fuse 10A, 40A I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between ECM and fuse block I Harness for open or short between fuse block and ignition switch. Refer to wiring diagram. ©

4

Repair harness or connectors.

CHECK POWER SUPPLY-II

1. Stop engine. 2. Check voltage between ECM terminals 67 and ground with CONSULT-II or tester.

SEF982W

Voltage: Battery voltage OK or NG © ©

OK NG

5

GO TO 6. GO TO 5.

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I 10A fuse I Harness for open or short between ECM and fuse ©

6

Repair harness or connectors.

CHECK POWER SUPPLY-III

1. Turn ignition switch “ON” and then “OFF”. 2. Check voltage between ECM terminals 110, 112 and ground with CONSULT-II or tester.

SEF983W

Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK NG (Battery voltage does not exist.) NG (Battery voltage exists for more than a few seconds.)

© ©

GO TO 14. GO TO 7.

©

GO TO 13.

EC-117

TROUBLE DIAGNOSIS FOR POWER SUPPLY

SR20DE

Main Power Supply and Ground Circuit (Cont’d)

7

CHECK HARNESS CONTINUITY BETWEEN ECM RELAY AND ECM

1. Disconnect ECM harness connector. 2. Disconnect ECM relay.

SEF984W

3. Check harness continuity between ECM terminals 110, 112 and relay terminal 5. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 9.

NG

©

GO TO 8.

8

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and ECM ©

9

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK VOLTAGE BETWEEN ECM RELAY AND GROUND

Check voltage between relay terminals 1, 3 and ground with CONSULT-II or tester.

SEF985W

Voltage: Battery voltage OK or NG OK

©

GO TO 11.

NG

©

GO TO 10.

10

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM relay and fuse. ©

Repair harness or connectors.

EC-118

TROUBLE DIAGNOSIS FOR POWER SUPPLY

SR20DE

Main Power Supply and Ground Circuit (Cont’d)

11

CHECK OUTPUT SIGNAL CIRCUIT

1. Check harness continuity between ECM terminal 31 and relay terminal 2. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 13.

NG

©

GO TO 12.

12

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E42, F4 I Harness for open or short between ECM relay and ECM ©

13

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ECM RELAY

1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5, 6 and 7.

SEC202BC

12V (1 - 2) applied: Continuity exists. No voltage applied: No continuity OK or NG OK

©

GO TO 14.

NG

©

Replace ECM relay.

14

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 48, 57, 106, 108 and engine ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 15.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

15

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

EC-119

SR20DE

DTC P0100 MASS AIR FLOW SENSOR (MAFS) Component Description

Component Description

SEF987W

NCEC0050

The mass air flow sensor is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. It consists of a hot wire that is supplied with electric current from the ECM. The temperature of the hot wire is controlled by the ECM a certain amount. The heat generated by the hot wire is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0051

Specification data are reference values. MONITOR ITEM

MAS A/F SE -B1

CAL/LD VALUE

MASS AIRFLOW

CONDITION

SPECIFICATION

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

1.0 - 1.7V

2,500 rpm

1.5 - 2.4V

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

Not used

2,500 rpm

Not used

I I I I

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

Idle

2.5 - 5.0 g⋅m/s

2,500 rpm

7.1 - 12.5 g⋅m/s

ECM Terminals and Reference Value

NCEC0052

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

61

73

WIRE COLOR

B

ITEM

Mass air flow sensor

Mass air flow sensor ground

W

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

1.3 - 1.7V

[Engine is running] I Warm-up condition I Engine speed is 2,500 rpm

1.8 - 2.4V

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V

On Board Diagnosis Logic DTC No. P0100* 0100

Malfunction is detected when ...

NCEC0053

Check Items (Possible Cause)

A)

An excessively high voltage from the sensor is sent to ECM when engine is not running.

I Harness or connectors (The sensor circuit is open or shorted.) I Mass air flow sensor

B)

An excessively low voltage from the sensor is sent to ECM when engine is running.

I Harness or connectors (The sensor circuit is open or shorted.) I Intake air leaks I Mass air flow sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up.

EC-120

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE

DTC Confirmation Procedure Detected items

Engine operating condition in fail-safe mode Engine speed will not rise more than 2,400 rpm due to the fuel cut.

Mass air flow sensor circuit

DTC Confirmation Procedure

NCEC0054

Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

PROCEDURE FOR MALFUNCTION A

NCEC0054S05

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-123. With GST Follow the procedure “With CONSULT-II” above. NEF068A

PROCEDURE FOR MALFUNCTION B

NCEC0054S06

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and wait 2 seconds at most. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-123. With GST Follow the procedure “With CONSULT-II” above. NEF068A

EC-121

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0056

YEC081A

EC-122

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0057

INSPECTION START

Which malfunction (A or B) is duplicated? Malfunction A or B A

©

GO TO 3.

B

©

GO TO 2.

2

CHECK INTAKE SYSTEM

Check the following for connection. I Air cut I Vacuum hoses I Intake air passage between air duct to collector OK or NG OK

©

GO TO 3.

NG

©

Reconnect the parts.

3

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

GO TO 4.

EC-123

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE

Diagnostic Procedure (Cont’d)

4

CHECK POWER SUPPLY-I

1. Disconnect mass air flow sensor harness connector. Mass air flow sensor harness connector

Air cleaner SEF203X

2. Turn ignition switch “ON”. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF996W

Voltage: Battery voltage OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ECM relay and mass air flow sensor I Harness for open or short between mass air flow sensor and ECM

©

Repair harness or connectors.

EC-124

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE

Diagnostic Procedure (Cont’d)

6

CHECK POWER SUPPLY-II

Check voltage between terminal 4 and ground with CONSULT-II or tester.

SEF201X

Voltage: 5V OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the harness for open or short between mass air flow sensor terminal 4 and ECM terminal 111. ©

8

Repair harness.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor harness connector terminal 3 and ECM terminal 73. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 9.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

9

CHECK INPUT SIGNAL CIRCUIT

1. Check harness continuity between mass air flow sensor harness connector terminal 5 and ECM terminal 61. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 10.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

10

CHECK MASS AIR FLOW SENSOR

Refer to “Component Inspection”, EC-SR-126. OK or NG OK

©

GO TO 11.

NG

©

Replace mass air flow sensor.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

EC-125

DTC P0100 MASS AIR FLOW SENSOR (MAFS)

SR20DE

Component Inspection

Component Inspection

NCEC0058

MASS AIR FLOW SENSOR 1. 2. 3.

Conditions Ignition switch “ON” (Engine stopped.) SEF993W

NCEC0058S01

Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 61 (Mass air flow sensor signal) and ground. Voltage V Less than 1.2

Idle (Engine is warmed-up to normal operating temperature.)

1.3 - 1.7

2,500 rpm (Engine is warmed-up to normal operating temperature.)

1.8 - 2.4

Idle to about 4,000 rpm*

1.3 - 1.7 to Approx. 4.0

*: Check for linear voltage rise in response to increases to about 4,000 rpm in engine speed.

4. SEF987W

5.

If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Repeat above check. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.

EC-126

SR20DE

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

Component Description

Component Description

NCEC0066

The intake air temperature sensor is built into the mass air flow sensor. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise.

SEF987W

Intake air temperature °C (°F)

Resistance kΩ

20 (68)

2.2 - 2.6

80 (176)

0.31 - 0.37

*: These data are reference values and are measured between ECM terminal 64 (Intake air temperature sensor) and ECM terminal 48 (ECM ground). SEF012P

On Board Diagnosis Logic DTC No. P0110 0110

Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM.

NCEC0067

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Intake air temperature sensor

DTC Confirmation Procedure

NCEC0068

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-129. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) 4)

NEF068A

EC-127

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0069

: Detectable line for DTC : Non-detectable line for DTC INTAKE AIR TEMPERATURE SENSOR

: Hyper CVT models

ECM

YEC830

EC-128

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0070

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect mass air flow sensor harness connector. Mass air flow sensor harness connector

Air cleaner SEF203X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester.

NEF228A

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and intake air temperature sensor

©

Repair harness or connectors.

EC-129

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between intake air temperature sensor (mass air flow sensor) harness connector terminal 3 and ECM terminal 73. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and intake air temperature sensor

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INTAKE AIR TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-SR-131. OK or NG OK

©

GO TO 6.

NG

©

Replace mass air flow sensor.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-130

SR20DE

DTC P0110 INTAKE AIR TEMPERATURE SENSOR

Component Inspection

Component Inspection

NCEC0071

INTAKE AIR TEMPERATURE SENSOR

NCEC0071S01

Check resistance between mass air flow sensor terminal 1 and 3. Intake air temperature °C (°F)

Resistance kΩ

20 (68)

2.2 - 2.6

80 (176)

0.31 - 0.37

SEF012P

If NG, replace mass air flow sensor.

EC-131

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)

SR20DE

Component Description

Component Description

NCEC0072

The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases.

SEF594K

Engine coolant temperature °C (°F)

Voltage* V

Resistance kΩ

−10 (14)

4.4

7.0 - 11.4

20 (68)

3.5

2.1 - 2.9

50 (122)

2.2

0.68 - 1.00

90 (194)

0.9

0.236 - 0.260

SEF012P

*: These data are reference values and are measured between ECM terminal 70 (Engine coolant temperature sensor) and ECM terminal 48 (ECM ground).

CONSULT-II Reference Value in Data Monitor Mode

NCEC0073

MONITOR ITEM COOLAN TEMP/S

CONDITION

SPECIFICATION

I Engine: After warming up

More than 70°C (158°F)

On Board Diagnosis Logic DTC No. P0115 0115

Malfunction is detected when ... I An excessively high or low voltage from the sensor is sent to ECM.*

NCEC0074

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Engine coolant temperature sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items

Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. Engine coolant temperature decided (CONSULT-II display)

Condition Engine coolant temperature sensor circuit

Just as ignition switch is turned ON or Start

40°C (104°F)

More than approx. 4 minutes after ignition ON or Start

80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time)

Except as shown above

When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while the engine is running.

EC-132

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

PEF002P

NCEC0075

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Wait at least 5 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-135. With GST Follow the procedure “With CONSULT-II” above.

EC-133

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0076

YEC082A

EC-134

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0077

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect engine coolant temperature sensor harness connector. Front exhaust tube

Coolant temperature sensor harness connector

Front SEF205X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF997W

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and engine coolant temperature sensor.

©

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between engine coolant temperature sensor harness connector terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-135

DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)

SR20DE

Component Inspection

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and engine coolant temperature sensor I Harness for open or short between engine coolant temperature sensor and TCM (Transmission control module)

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Refer to “Component Inspection”, EC-SR-136. OK or NG OK

©

GO TO 6.

NG

©

Replace engine coolant temperature sensor.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection

NCEC0078

ENGINE COOLANT TEMPERATURE SENSOR Check resistance as shown in the figure.

SEF152P

Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

If NG, replace engine coolant temperature sensor. SEF012P

EC-136

NCEC0078S01

SR20DE

DTC P0120 THROTTLE POSITION SENSOR

Component Description

Component Description

NCEC0079

NOTE: If DTC P0120 (0120) is displayed with DTC P0510 (0510), first perform trouble diagnosis for DTC P0510, EC-SR-271. The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the ECM. Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sensor. This sensor controls engine operation such as fuel cut. On the other hand, the “Wide open and closed throttle position switch”, which is built into the throttle position sensor unit, is not used for engine control.

YEC118A

CONSULT-II Reference Value in Data Monitor Mode

NCEC0080

Specification data are reference values. MONITOR ITEM

THRTL POS SEN

ABSOL TH⋅P/S

CONDITION

SPECIFICATION

I Engine is idling.

Throttle valve: fully closed

0.35 - 0.65V

I Ignition switch: ON (Engine stopped)

Throttle valve: fully opened

3.5 - 4.5V

I Engine: Idle the engine

Throttle valve: fully closed

0.0°

I Ignition switch: ON (Engine stopped)

Throttle valve: fully opened

Approx. 80°

EC-137

SR20DE

DTC P0120 THROTTLE POSITION SENSOR ECM Terminals and Reference Value

ECM Terminals and Reference Value

=NCEC0081

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58

92

111

WIRE COLOR

B

ITEM

CONDITION

Sensors’ ground

Y

Throttle position sensor

G

Sensors’ power supply

DATA (DC Voltage)

[Engine is running] I Warm up condition I Idle speed

Approximately 0V

[Engine is running] I Accelerator pedal fully released

0.35 - 0.65V

[Ignition switch “ON”] I Accelerator pedal fully depressed

Approximately 4.0V

[Ignition switch “ON”]

Approximately 5V

On Board Diagnosis Logic DTC No. P0120 0120

Malfunction is detected when ... An excessively low or high voltage from the sensor is sent to ECM while driving*.

NCEC0082

Check Items (Possible Cause) I Harness or connectors (The throttle position sensor circuit is open or shorted.) I Throttle position sensor

*: When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items

Engine operating condition in fail-safe mode Throttle position will be determined based on the injected fuel amount and the engine speed. Therefore, acceleration will be poor.

Throttle position sensor circuit

Condition

Driving condition

When engine is idling

Normal

When accelerating

Poor acceleration

DTC Confirmation Procedure

NCEC0083

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: I Before performing the following procedure, confirm that battery voltage is more than 10V at idle. I This test may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-138

DTC P0120 THROTTLE POSITION SENSOR

SR20DE

DTC Confirmation Procedure (Cont’d)

With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and maintain the following conditions for at least 5 consecutive seconds.

PEF651U

VHCL SPEED SE

More than 4 km/h (2 MPH)

Selector lever

Suitable position except “P” or “N” position

3)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-141. With GST Follow the procedure “With CONSULT-II” above.

EC-139

DTC P0120 THROTTLE POSITION SENSOR

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0084

YEC083A

EC-140

DTC P0120 THROTTLE POSITION SENSOR

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0085

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CHECK POWER SUPPLY

1. Disconnect throttle position sensor harness connector. Throttle position sensor harness connector

Throttle body

Closed throttle position switch harness connector (CVT models)

SEF197X

2. Turn ignition switch “ON”. 3. Check voltage between terminal 3 and ground with CONSULT-II or tester.

SEF209W

Voltage: Approximately 5V OK or NG OK

©

GO TO 3.

NG

©

Repair harness or connectors.

3

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between throttle position sensor harness connector terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-141

SR20DE

DTC P0120 THROTTLE POSITION SENSOR Component Inspection

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between ECM and throttle position sensor I Harness for open or short between throttle position sensor and TCM (Transmission control module)

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 92 and throttle position sensor harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK THROTTLE POSITION SENSOR

Refer to “Component Inspection”, EC-SR-142. OK or NG OK

©

GO TO 7.

NG

©

Replace throttle position sensor. To adjust it, perform “Basic Inspection”, EC-SR-84.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection

NCEC0086

THROTTLE POSITION SENSOR

NEF069A

NCEC0086S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine (ignition switch OFF). 3) Turn ignition switch ON. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Check voltage of “THRTL POS SEN” under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. Throttle valve conditions Completely closed Partially open Completely open

Voltage V 0.35 - 0.65 (a) Between (a) and (b) 3.5 - 4.5 (b)

If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-SR-84.

EC-142

SR20DE

DTC P0120 THROTTLE POSITION SENSOR

Component Inspection (Cont’d)

6)

If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.

Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine (ignition switch OFF). Turn ignition switch ON. Check voltage between ECM terminal 92 (Throttle position sensor signal) and ground under the following conditions. NOTE: Voltage measurement must be made with throttle position sensor installed in vehicle. 1) 2) 3) 4)

SEF007X

Throttle valve conditions Completely closed Partially open Completely open

5)

Voltage V 0.35 - 0.65 (a) Between (a) and (b) Approx. 4.0 (b)

If NG, adjust throttle position sensor idle position. Refer to “Basic Inspection”, EC-SR-84. If it is impossible to adjust throttle position sensor idle position in “Basic Inspection”, replace throttle position sensor.

EC-143

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE

Component Description

Component Description

NCEC0094

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NCEC0095

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NCEC0096

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL NO. COLOR

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-144

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0097

Under the condition in which the heated oxygen sensor 1 (front) signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long.

SEF237U

DTC No. P0130 0130

Malfunction is detected when ... I The voltage from the sensor is constantly approx. 0.3V.

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)

DTC Confirmation Procedure

SEF825Y

SEF826Y

SEF645Y

NCEC0098

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “HO2S1 (B1) P0130” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 3) Touch “START”. 4) Let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 4. 5) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.) ENG SPEED

1,500 - 3,200 rpm

Vehicle speed

64 - 130 km/h (40 - 81 MPH)

B/FUEL SCHDL

2.4 - 11.0 msec

Selector lever

Suitable position

If “TESTING” is not displayed after 5 minutes, retry from step 2.

EC-145

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE

Overall Function Check

6)

Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-148.

Overall Function Check

SEF011X

NCEC0099

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The voltage does not remain in the range of 0.2 - 0.4V. 4) If NG, go to “Diagnostic Procedure”, EC-SR-148.

EC-146

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0100

YEC084A

EC-147

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0101

INSPECTION START

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

3. Disconnect heated oxygen sensor 1 (front) harness connector.

Heated oxygen sensor 1 (front) harness connector

Heated oxygen sensor 1 (front) SEF207X

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-149. OK or NG OK

©

GO TO 4.

NG

©

Replace heated oxygen sensor 1 (front).

4

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-148

DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)

SR20DE Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

NCEC0102S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

FR O2 SENSOR x0.01V

-09″99 -02″89

SEF647Y

NCEC0102

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1) 2)

SEF011X

EC-149

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE

Component Description

Component Description

NCEC0103

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NCEC0104

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NCEC0105

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-150

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0106

To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected.

SEF300U

DTC No. P0131 0131

Malfunction is detected when ... I The maximum and minimum voltages from the sensor are not reached to the specified voltages.

Check Items (Possible Cause) I I I I I

Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater Fuel pressure Injectors Intake air leaks

DTC Confirmation Procedure

SEF827Y

SEF828Y

NCEC0107

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 P0131” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 20 seconds or more.)

SEF651Y

EC-151

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE

DTC Confirmation Procedure (Cont’d) ENG SPEED

1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)

Vehicle speed

80 - 120 km/h (50 - 75 MPH)

B/FUEL SCHDL

4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)

Selector lever

Suitable position

7)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-153.

Overall Function Check

SEF011X

NCEC0108

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is over 0.6V at least one time. I The minimum voltage is over 0.1V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-SR-153.

EC-152

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0109

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)

©

2

GO TO 2.

CLEAR THE SELF-LEARNING DATA.

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171. Refer to EC-SR-212.

No

©

GO TO 3.

EC-153

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER

Refer to “Component Inspection”, EC-SR-179. OK or NG OK

©

GO TO 4.

NG

©

Replace heated oxygen sensor 1 (front).

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-154. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. Refer to “Wiring Diagram”, EC-SR-147, for circuit.

©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

NCEC0110 NCEC0110S02

With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1) 2)

SEF646Y

FR O2 SENSOR x0.01V

-09″99 -02″89

SEF647Y

SEF648Y

EC-154

DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)

SR20DE

Component Inspection (Cont’d)

SEF011X

Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

EC-155

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE

Component Description

Component Description

NCEC0111

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NCEC0112

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NCEC0113

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-156

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE On Board Diagnosis Logic

On Board Diagnosis Logic OK

NCEC0114

To judge the malfunction, the output from the heated oxygen sensor 1 (front) is monitored to determine whether the “rich” output is sufficiently high. The “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected.

NG

1V 0.8V

0.35V 0V SEF299U

DTC No. P0132 0132

Malfunction is detected when ... I The maximum and minimum voltages from the sensor are beyond the specified voltages.

Check Items (Possible Cause) I I I I

Heated oxygen sensor 1 (front) Heated oxygen sensor 1 (front) heater Fuel pressure Injectors

DTC Confirmation Procedure

SEF829Y

SEF830Y

NCEC0115

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0132” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 20 seconds or more.)

SEF655Y

EC-157

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE

DTC Confirmation Procedure (Cont’d) ENG SPEED

1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)

Vehicle speed

80 - 120 km/h (50 - 75 MPH)

B/FUEL SCHDL

4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)

Selector lever

Suitable position

7)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-159.

Overall Function Check

SEF011X

NCEC0116

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I The maximum voltage is below 0.8V at least one time. I The minimum voltage is below 0.35V at least one time. 4) If NG, go to “Diagnostic Procedure”, EC-SR-159.

EC-158

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

=NCEC0117

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

1. Turn ignition switch “OFF”. 2. Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)

©

2

GO TO 2.

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.

No

©

GO TO 3.

EC-159

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK HARNESS CONNECTOR

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector. 3. Check harness connector for water. Water should not exit. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace harness connector.

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER

Refer to “Component Inspection”, EC-SR-179. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-160. OK or NG OK

©

GO TO 6.

NG

©

Replace heated oxygen sensor 1 (front).

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. Refer to “Wiring Diagram”, EC-SR-147, for circuit.

©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

SEF647Y

NCEC0118 NCEC0118S02

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

EC-160

DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)

SR20DE

FR O2 SENSOR x0.01V

-09″99 -02″89

Component Inspection (Cont’d)

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than 5 times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1) 2)

SEF011X

EC-161

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE

Component Description

Component Description

NCEC0119

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NCEC0120

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NCEC0121

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-162

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0122

To judge the malfunction of heated oxygen sensor 1 (front), this diagnosis measures response time of heated oxygen sensor 1 (front) signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 (front) temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 (front) cycling time index) is inordinately long or not. SEF010V

DTC No. P0133 0133

Malfunction is detected when ...

Check Items (Possible Cause)

I The response of the voltage signal from the sensor takes I Harness or connectors more than the specified time. (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front) I Heated oxygen sensor 1 (front) heater I Fuel pressure I Injectors I Intake air leaks I Exhaust gas leaks I PCV I Mass air flow sensor

DTC Confirmation Procedure

SEF831Y

SEF832Y

NCEC0123

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3.5 minutes. NOTE: Never raise engine speed above 3,200 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 20 seconds.)

SEF658Y

EC-163

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE

DTC Confirmation Procedure (Cont’d) ENG SPEED

1,800 - 2,900 rpm (CVT) 2,000 - 3,100 rpm (M/T)

Vehicle speed

80 - 120 km/h (50 - 75 MPH)

B/FUEL SCHDL

4.5 - 14.0 msec (CVT) 3.5 - 12.0 msec (M/T)

Selector lever

Suitable position

7)

If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-166.

Overall Function Check

SEF011X

NCEC0124

Use this procedure to check the overall function of the heated oxygen sensor 1 (front) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). 4) If NG, go to “Diagnostic Procedure”, EC-SR-166.

EC-164

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0125

YEC084A

EC-165

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0126

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)

©

3

GO TO 3.

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

SEF099P

OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 5.

NG

©

Repair or replace.

EC-166

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

5

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 or 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171, P0172. Refer to EC-SR-212, 218.

No

©

GO TO 6.

6

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 7.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-167

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING) Diagnostic Procedure (Cont’d)

7

CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER

Refer to “Component Inspection”, EC-SR-179. OK or NG OK

©

GO TO 8.

NG

©

Replace heated oxygen sensor 1 (front).

8

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-169. OK or NG OK

©

GO TO 9.

NG

©

Replace heated oxygen sensor 1 (front).

9

CHECK MASS AIR FLOW SENSOR

Refer to “Component Inspection”, EC-SR-126. OK or NG OK

©

GO TO 10.

NG

©

Replace mass air flow sensor.

10

CHECK PCV VALVE

Refer to “Positive Crankcase Ventilation”, EC-SR-30. OK or NG OK

©

GO TO 11.

NG

©

Repair or replace PCV valve.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-168

SR20DE

DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)

SR20DE Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (B1)

SEF646Y

NCEC0127S02

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

FR O2 SENSOR x0.01V

-09″99 -02″89

SEF647Y

NCEC0127

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1) 2)

SEF011X

EC-169

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

SR20DE

Component Description

Component Description

NCEC0128

The heated oxygen sensor 1 (front) is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 (front) has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 (front) signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R

SEF288D

CONSULT-II Reference Value in Data Monitor Mode

NCEC0129

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S1 (B1) HO2S1 MNTR (B1)

I Engine: After warming up

Maintaining engine speed at 2,000 rpm

LEAN +, RICH Changes more than 5 times during 10 seconds.

ECM Terminals and Reference Value

NCEC0130

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) 0 - Approximately 1.0V

62

R

Heated oxygen sensor 1 (front)

[Engine is running] I After warming up to normal operating temperature and engine speed is 2,000 rpm SEF008W

EC-170

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

SR20DE On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0131

To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 (front) output is not inordinately high.

SEF301U

DTC No. P0134 0134

Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 1 (front)

DTC Confirmation Procedure

SEF058Y

NCEC0132

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON”. 4) Select “DATA MONITOR” mode with CONSULT-II. 5) Restart engine and let it idle for 2 minutes. 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-173. With GST 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Restart engine and let it idle for 2 minutes. 4) Turn ignition switch “OFF” and wait at least 9 seconds. 5) Restart engine and let it idle for 2 minutes. 6) Select “MODE 3” with GST. 7) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-173. I When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.

EC-171

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0133

YEC084A

EC-172

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0134

RETIGHTEN HEATED OXYGEN SENSOR 1 (FRONT)

Loosen and retighten heated oxygen sensor 1 (front). Tightening torque: 40 - 60 N⋅m (4.1 - 6.1 kg-m, 30 - 44 ft-lb)

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.

Heated oxygen sensor 1 (front) harness connector

Heated oxygen sensor1 (front) SEF207X

2. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 1 (front) harness connector for water. Water should not exist. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace harness connector.

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-174. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-173

DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)

SR20DE

Component Inspection

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT)

SEF646Y

NCEC0135S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode, and select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. 3) Hold engine speed at 2,000 rpm under no load during the following steps. 4) Touch “RECORD” on CONSULT-II screen. 5) Check the following. I “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” five times in 10 seconds. 5 times (cycles) are counted as shown below: R = “HO2S1 MNTR (B1)”, “RICH” L = “HO2S1 MNTR (B1)”, “LEAN” I “HO2S1 (B1)” voltage goes above 0.6V at least once. I “HO2S1 (B1)” voltage goes below 0.3V at least once. I “HO2S1 (B1)” voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

FR O2 SENSOR x0.01V

-09″99 -02″89

SEF647Y

NCEC0135

SEF648Y

Without CONSULT-II Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 62 (Heated oxygen sensor 1 (front) signal) and engine ground. 3) Check the following with engine speed held at 2,000 rpm constant under no load. I Malfunction indicator goes on more than five times within 10 seconds in Diagnostic Test Mode II (HEATED OXYGEN SENSOR 1 (FRONT) MONITOR). I The maximum voltage is over 0.6V at least one time. I The minimum voltage is below 0.3V at least one time. I The voltage never exceeds 1.0V. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1) 2)

SEF011X

EC-174

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Description

Description

NCEC0136

SYSTEM DESCRIPTION

NCEC0136S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen sensor Heated oxygen sensor 1 (front) 1 (front) heater heater control

Engine speed

The ECM performs ON/OFF control of the heated oxygen sensor 1 (front) heater corresponding to the engine operating condition.

OPERATION

NCEC0136S02

Engine speed

Heated oxygen sensor 1 (front) heater

Above 3,200 rpm

OFF

More than 20 seconds after exceeding 3,200 rpm

ON

CONSULT-II Reference Value in Data Monitor Mode

NCEC0137

Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1)

CONDITION

SPECIFICATION

I Engine speed: Below 3,200 rpm

ON

I More than 20 seconds after exceeding 3,200 rpm

OFF

ECM Terminals and Reference Value

NCEC0138

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

4

WIRE COLOR

L

ITEM

Heated oxygen sensor 1 (front) heater

CONDITION

DATA (DC Voltage)

[Engine is running] I Engine speed is below 3,200 rpm.

Approximately 0V

[Engine is running] I More than 20 seconds after exceeding 3,200 rpm.

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P0135 0135

Malfunction is detected when ... I The current amperage in the heated oxygen sensor 1 (front) heater circuit is out of the normal range. (An improper voltage drop signal is sent to ECM through the heated oxygen sensor 1 (front) heater.)

NCEC0139

Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 1 (front) heater circuit is open or shorted.) I Heated oxygen sensor 1 (front) heater

DTC Confirmation Procedure

NCEC0140

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at idle.

EC-175

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE DTC Confirmation Procedure (Cont’d)

1) 2) 3)

NEF068A

1) 2) 3) 4) 5) I

With CONSULT-II Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-178. With GST Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch “OFF” and wait at least 9 seconds. Start engine and run it for at least 5 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-SR-178. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended.

EC-176

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Wiring Diagram

Wiring Diagram

NCEC0141

YEC085A

EC-177

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0142

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector.

Heated oxygen sensor 1 (front) harness connector

Heated oxygen sensor 1 (front) SEF207X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 3 and ground with CONSULT or tester. DISCONNECT

SEF025X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 (M81, F115 for CVT models) I 10A fuse I Harness for open or short between heated oxygen sensor 1 (front) and fuse

©

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 1 (front) harness connector terminal 1 and ECM terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-178

DTC P0135 HEATED OXYGEN SENSOR 1 (FRONT) HEATER SR20DE Component Inspection

4

CHECK HEATED OXYGEN SENSOR 1 (FRONT) HEATER

Refer to “Component Inspection”, EC-SR-179. OK or NG OK

©

GO TO 5.

NG

©

Replace heated oxygen sensor 1 (front).

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection HEATED OXYGEN SENSOR 1 (FRONT) HEATER DISCONNECT

SEF026X

NCEC0143 NCEC0143S01

Check resistance between terminals 3 and 1. Resistance: 2.3 - 4.3 Ω at 25°C (77°F) Check continuity between terminals 2 and 1, 3 and 2. Continuity should not exist. If NG, replace the heated oxygen sensor 1 (front). CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

EC-179

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE

Component Description

Component Description

SEF327R

NCEC0144

The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0145

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NCEC0146

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63

WIRE COLOR

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

L

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 3,000 rpm

On Board Diagnosis Logic OK 1V 0.43V

0V

SEF258V

DTC No. P0137 0137

NCEC0147

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the minimum voltage of the sensor is sufficiently low during various driving conditions such as fuel-cut.

NG

Malfunction is detected when ... I The minimum voltage from the sensor does not reach the specified voltage.

EC-180

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF682X

SEF684X

NCEC0148

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0137” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)

Vehicle speed

68 - 130 km/h (42 - 81 MPH)

B/FUEL SCHDL

3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)

Selector lever

D position (CVT) 4th gear position (M/T)

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG

EC-181

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE

Overall Function Check

RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-184.

Overall Function Check

SEF032X

NCEC0149

Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving engine up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 0.43V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-184.

EC-182

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0150

YEC086A

EC-183

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0151

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.

No

©

GO TO 3.

EC-184

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector

Heated oxygen sensor 2 (rear)

Front exhaust tube SEF209X

3. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM.

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and body ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-SR-186. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-185

DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)

SR20DE

Component Inspection

Component Inspection

NCEC0152

HEATED OXYGEN SENSOR 2 (REAR)

SEF662Y

NCEC0152S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “RR O2 SEN -B1” should be above 0.48V at least once when the “FUEL INJECTION” is +25%.“HO2S2 (B1)” should be below 0.43V at least once when the “FUEL INJECTION” is −25%. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

x0.01V

(Reference data)

The voltage should be above 0.48V at least one time.

The voltage should be below 0.43V at least one time. SEF989R

CONNECT

Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1)

SEF032X

EC-186

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE Component Description

Component Description

SEF327R

NCEC0153

The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0154

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NCEC0155

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63

WIRE COLOR

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

L

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and engine speed is 2,000 rpm

On Board Diagnosis Logic OK 1V 0.43V

0V

SEF259V

DTC No. P0138 0138

NCEC0156

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the maximum voltage of the sensor is sufficiently high during various driving conditions such as fuel-cut.

NG

Malfunction is detected when ... I The maximum voltage from the sensor does not reach the specified voltage.

EC-187

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF685X

SEF687X

NCEC0157

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0138” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)

Vehicle speed

68 - 130 km/h (42 - 81 MPH)

B/FUEL SCHDL

3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)

Selector lever

D position (CVT) 4th gear position (M/T)

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG

EC-188

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE Overall Function Check

RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-191.

Overall Function Check

CONNECT

SEF032X

NCEC0158

Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving engine up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.48V at least once during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be above 0.48V at least once during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-191.

EC-189

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0159

YEC086A

EC-190

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0160

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0171 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0171. Refer to EC-SR-212.

No

©

GO TO 3.

EC-191

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. 2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and heated oxygen sensor 2 (rear).

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 3 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-SR-193. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-192

DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)

SR20DE Component Inspection

Component Inspection

NCEC0161

HEATED OXYGEN SENSOR 2 (REAR)

NEF091A

NCEC0161S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes.. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V at least once when the “FUEL INJECTION” is −25%. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

x0.01V

(Reference data)

The voltage should be above 0.48V at least one time.

The voltage should be below 0.43V at least one time. SEF989R

Without CONSULT-II Start engine and drive vehicle at a speed of 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1)

SEF032X

EC-193

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE

Component Description

Component Description

SEF327R

NCEC0162

The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0163

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NCEC0164

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63

WIRE COLOR

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

L

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm

On Board Diagnosis Logic OK

SEF302U

DTC No. P0139 0139

NCEC0165

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether the switching response of the sensor’s voltage is faster than specified during various driving conditions such as fuel-cut.

NG

Malfunction is detected when ... I It takes more than the specified time for the sensor to respond between rich and lean.

EC-194

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear) I Fuel pressure I Injectors I Intake air leaks

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE DTC Confirmation Procedure

DTC Confirmation Procedure

SEF688X

SEF690X

NCEC0166

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). I Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2. With CONSULT-II NOTE: The figure on the left will be displayed on the CONSULT-II screen when you start the DTC Work Support. Ignore the first figure and start the test. “COMPLETED” will be displayed on the screen as the second figure when the test is completed properly. 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 30 seconds. 6) Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 10. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 7) Drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 8) Additionally, “COMPLETED” will be displayed on the CONSULT-II screen when the accelerator pedal is completely released after the vehicle is driven for 60 seconds or more under the following conditions. (It will take approximately 5 seconds.) ENG SPEED

1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)

Vehicle speed

68 - 130 km/h (42 - 81 MPH)

B/FUEL SCHDL

3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)

Selector lever

D position (CVT) 4th gear position (M/T)

NOTE: I If “COMPLETED” appears on CONSULT-II screen, go to step 10. I If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9) Stop the vehicle and let it idle until “COMPLETED” is displayed on the CONSULT-II screen. (It will take 6 minutes at the most.) NOTE: If “COMPLETED” is not displayed after 6 minutes, retry from step 2. 10) Make sure that “OK” is displayed after touching “SELF-DIAG

EC-195

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE

Overall Function Check

RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-SR-198.

Overall Function Check

CONNECT

SEF032X

NCEC0167

Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should change at more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 4, step 5 is not necessary. 5) Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should change at more than 0.06V for 1 second during this procedure. 6) If NG, go to “Diagnostic Procedure”, EC-SR-198.

EC-196

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0168

YEC086A

EC-197

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0169

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CLEAR THE SELF-LEARNING DATA

With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”.

SEF652Y

4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch “OFF”. 3. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 3 seconds at idle speed. Mass air flow sensor harness connector

Air cleaner SEF203X

4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure diagnostic trouble code No. 0100 is displayed in Diagnostic Test Mode II. 6. Erase the diagnostic test mode II (Self-diagnostic results) memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-SR-56. 7. Make sure diagnostic trouble code No. 0000 is displayed in Diagnostic Test Mode II. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC 0172 detected? Is it difficult to start engine? Yes or No Yes

©

Perform trouble diagnosis for DTC P0172. Refer to EC-SR-218.

No

©

GO TO 3.

EC-198

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE

Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector

Heated oxygen sensor 2 (rear)

Front exhaust tube SEF209X

2. Check harness continuity between ECM terminal 63 and rear heated oxygen harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM.

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-SR-200. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-199

DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING)

SR20DE

Component Inspection

Component Inspection

NCEC0170

HEATED OXYGEN SENSOR 2 (REAR)

SEF662Y

NCEC0170S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V at least once when the “FUEL INJECTION” is −25%. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

x0.01V

(Reference data)

The voltage should be above 0.48V at least one time.

The voltage should be below 0.43V at least one time. SEF989R

Without CONSULT-II Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. 1)

SEF032X

EC-200

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE Component Description

Component Description

SEF327R

NCEC0171

The heated oxygen sensor 2 (rear) (Rear HO2S), after three way catalyst, monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 (front) are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2 (rear). This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 (rear) is not used for engine control operation.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0172

Specification data are reference values. MONITOR ITEM

CONDITION

SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V

HO2S2 (B1) I Engine: After warming up

HO2S2 MNTR (B1)

Revving engine from idle to 3,000 rpm

LEAN +, RICH

ECM Terminals and Reference Value

NCEC0173

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 63

WIRE COLOR

ITEM

CONDITION

Heated oxygen sensor 2 (rear)

L

DATA (DC Voltage)

[Engine is running] I After warming up to normal operating temperature 0 - Approximately 1.0V and revving engine from idle to 2,000 rpm

On Board Diagnosis Logic OK

SEF305U

DTC No. P0140 0140

NCEC0174

The heated oxygen sensor 2 (rear) has a much longer switching time between rich and lean than the heated oxygen sensor 1 (front). The oxygen storage capacity before the three way catalyst causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2 (rear), ECM monitors whether or not the voltage is too high during various driving conditions such as fuelcut.

NG

Malfunction is detected when ... I An excessively high voltage from the sensor is sent to ECM.

EC-201

Check Items (Possible Cause) I Harness or connectors (The sensor circuit is open or shorted.) I Heated oxygen sensor 2 (rear)

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NEF102A

ENG SPEED

1,650 - 3,600 rpm (CVT) 1,500 - 3,600 rpm (M/T)

VHCL SPEED SE

68 - 130 km/h (42 - 81 MPH)

B/FUEL SCHDL

3.2 - 15.0 msec (CVT) 3.2 - 13.5 msec (M/T)

COOLAN TEMP/S

70 - 100°C (158 - 212°F)

Selector lever

Suitable position

6)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-204.

Overall Function Check

SEF032X

NCEC0175

NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) Stop vehicle with engine running. 4) Let engine idle for 1 minute. 5) Maintain the following conditions for at least 5 consecutive seconds.

NCEC0176

Use this procedure to check the overall function of the heated oxygen sensor 2 (rear) circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage after revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 2V during this procedure. 5) If NG, go to “Diagnostic Procedure”, EC-SR-204.

EC-202

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0177

YEC086A

EC-203

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0178

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect heated oxygen sensor 2 (rear) harness connector and ECM harness connector. Heated oxygen sensor 2 (rear) harness connector

Heated oxygen sensor 2 (rear)

Front exhaust tube SEF209X

2. Check harness continuity between ECM terminal 63 and heated oxygen sensor 2 (rear) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 3. Check harness continuity between ECM terminal 63 (or terminal 2) and ground. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) and ECM. ©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 4 and engine ground. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-204

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE Component Inspection

5

CHECK HARNESS CONNECTOR

Check heated oxygen sensor 2 (rear) harness connector for water. Water should not exist. OK or NG OK

©

GO TO 6.

NG

©

Repair or replace harness connector.

6

CHECK HEATED OXYGEN SENSOR 2 (REAR)

Refer to “Component Inspection”, EC-SR-205. OK or NG OK

©

GO TO 7.

NG

©

Replace heated oxygen sensor 2 (rear).

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection REAR HEATED OXYGEN SENSOR

x0.01V

SEF662Y

NCEC0179 NCEC0179S01

With CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. 4) Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. “HO2S2 (B1)” should be above 0.48V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.43V at least once when the “FUEL INJECTION” is −25%. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. (Reference data)

The voltage should be above 0.48V at least one time.

The voltage should be below 0.43V at least one time. SEF989R

EC-205

DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)

SR20DE

Component Inspection (Cont’d)

SEF032X

Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeter probes between ECM terminals 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.48V at least once. If the voltage is above 0.48V at step 4, step 5 is not necessary. 5) Check the voltage when revving up to 6,000 rpm under no load. Or keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), D position with “SPORTS MODE SW” OFF or without “MANUAL MODE” (CVT). The voltage should be below 0.43V at least once. CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

EC-206

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER

SR20DE Description

Description

NCEC0180

SYSTEM DESCRIPTION

NCEC0180S01

Sensor

ECM function

Input Signal to ECM

Camshaft position sensor

Actuator

Heated oxygen sensor Heated oxygen sensor 2 (rear) 2 (rear) heater heater control

Engine speed

The ECM performs ON/OFF control of the heated oxygen sensor 2 (rear) heater corresponding to the engine speed.

OPERATION

NCEC0180S02

Engine condition

Heated oxygen sensor 2 (rear) heater

Engine stopped

OFF

Engine is running below 3,600 rpm. [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

CONSULT-II Reference Value in Data Monitor Mode

NCEC0181

Specification data are reference values. MONITOR ITEM

HO2S2 HTR (B1)

CONDITION

SPECIFICATION

I Engine speed: Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

ON

I Ignition switch ON (Engine stopped)

OFF

ECM Terminals and Reference Value

NCEC0182

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERWIRE MINAL COLOR NO.

3

W/R

ITEM

Heated oxygen sensor 2 (rear) heater

CONDITION

DATA (DC Voltage)

[Engine is running] I Below 3,600 rpm [After driving for 2 minutes at a speed of 70 km/h (43 MPH) or more]

Approximately 0.7V

[Ignition switch “ON”] I Engine stopped

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P0141 0141

Malfunction is detected when ... I The current amperage in the heated oxygen sensor 2 (rear) heater circuit is out of the normal range. (An improper voltage drop signal is sent to ECM through the heated oxygen sensor 2 (rear) heater.)

EC-207

NCEC0183

Check Items (Possible Cause) I Harness or connectors (The heated oxygen sensor 2 (rear) heater circuit is open or shorted.) I Heated oxygen sensor 2 (rear) heater

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NCEC0184

NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is in between 10.5V and 16V at idle.

With CONSULT-II Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-210. With GST 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 4) Select “MODE 3” with GST. 5) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-210. When using GST, “DTC Confirmation Procedure ” should be performed twice as much as when using CONSULT-II or ECM (Diagnostic Test Mode II) because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II or ECM (Diagnostic Test Mode II) is recommended. 1)

NEF103A

EC-208

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER

SR20DE Wiring Diagram

Wiring Diagram

NCEC0185

YEC087A

EC-209

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0186

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 2 (rear) harness connector. Heated oxygen sensor 2 (rear) harness connector

Heated oxygen sensor 2 (rear)

Front exhaust tube

SEF209X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 4 and ground.

SEF047X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 (M81, F115 for CVT models) I Harness for open or short between heated oxygen sensor 2 (rear) and fuse ©

3

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between heated oxygen sensor 2 (rear) harness connector terminal 1 and ECM terminal 3. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between heated oxygen sensor 2 (rear) heater and ECM. ©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-210

DTC P0141 HEATED OXYGEN SENSOR 2 (REAR) HEATER

SR20DE

Component Inspection

5

CHECK HEATED OXYGEN SENSOR 2 (REAR) HEATER

Refer to “Component Inspection”, EC-SR-211. OK or NG OK

©

GO TO 6.

NG

©

Replace heated oxygen sensor 2 (rear).

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

Component Inspection

NCEC0187

HEATED OXYGEN SENSOR 2 (REAR) HEATER

NCEC0187S01

Check the following. 1. Check resistance between terminals 1 and 4. Resistance: 2.3 - 4.3Ω at 25°C (77°F) 2. Check continuity. Terminal No.

Continuity

2 and 1, 3, 4 No 3 and 1, 2, 4

If NG, replace the heated oxygen sensor 2 (rear). CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one.

SEF048X

EC-211

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0188

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1 (front). The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor

P0171 0171

Fuel injection & mixture ratio control

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Heated oxygen sensor 1 (front)

DTC No.

ECM function

Input Signal to ECM

Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.)

Actuator

Injectors

Check Items (Possible Cause) I I I I I I I

Intake air leaks Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor

DTC Confirmation Procedure

SEF652Y

SEF058Y

Mass air flow sensor harness connector

Air cleaner

NCEC0189

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-SR214. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-SR-214. If engine does not start, visually check for exhaust and intake air leak. With GST Follow the procedure “With CONSULT-II” above.

SEF203X

EC-212

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0190

YEC088A

EC-213

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0191

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before three way catalyst.

SEF099P

OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

2

CHECK FOR INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

3

CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.

Heated oxygen sensor 1 (front) harness connector

Heated oxygen sensor 1 (front) SEF207X

3. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-214

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE

Diagnostic Procedure (Cont’d)

4

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-SR-31. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit Refer to EC-SR-316. I Fuel pressure regulator Refer to EC-SR-32. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging

©

6

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK

©

GO TO 7.

NG

©

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-120.

EC-215

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE

Diagnostic Procedure (Cont’d)

7

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.

At idle

Suitable tool

MEC703B

Clicking noise should be heard. OK or NG OK

©

GO TO 8.

NG

©

Perform trouble diagnosis for “INJECTORS”, EC-SR-304.

8

REMOVE INJECTOR

1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector with fuel tube assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery. The injector harness connectors should remain connected.

©

GO TO 9.

EC-216

DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)

SR20DE

Diagnostic Procedure (Cont’d)

9

CHECK INJECTOR

1. Disconnect all ignition coil harness connectors. 2. Place pans or saucers under each injector. 3. Crank engine for about 3 seconds. Make sure that fuel sprays out from injectors.

SEF595Q

Fuel should be sprayed evenly for each cylinder. OK or NG OK

©

GO TO 10.

NG

©

Replace injectors from which fuel does not spray out. Always replace O-ring with new one.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-217

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0192

With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1 (front). The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as a fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor

Heated oxygen sensor 1 (front)

DTC No. P0172 0172

ECM function

Input Signal to ECM

Fuel injection & mixture ratio control

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Malfunction is detected when ... I Fuel injection system does not operate properly. I The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.)

Actuator

Injectors

Check Items (Possible Cause) I I I I I

Heated oxygen sensor 1 (front) Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor

DTC Confirmation Procedure

SEF652Y

SEF058Y

NCEC0193

NOTE: If “DTC Confirmation Procedure ” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 9 seconds. 3) Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. 4) Clear the self-learning control coefficient by touching “CLEAR”. 5) Select “DATA MONITOR” mode with CONSULT-II. 6) Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-SR221. 7) If it is difficult to start engine at step 6, the fuel injection system has a malfunction. 8) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-SR-221. If engine does not start, remove ignition plugs and check for fouling, etc.

EC-218

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE

DTC Confirmation Procedure (Cont’d)

With GST Follow the procedure “With CONSULT-II” above.

Mass air flow sensor harness connector

Air cleaner

SEF203X

EC-219

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0194

YEC088A

EC-220

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0195

CHECK FOR EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.

SEF099P

OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

2

CHECK HEATED OXYGEN SENSOR 1 (FRONT) CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 (front) harness connector and ECM harness connector.

Heated oxygen sensor 1 (front) harness connector

Heated oxygen sensor 1 (front) SEF207X

3. Check harness continuity between ECM terminal 62 and heated oxygen sensor 1 (front) harness connector terminal 2. Refer to wiring diagram. Continuity should exist. 4. Check harness continuity between ECM terminal 62 (or terminal 2) and ground. Continuity should not exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK FUEL PRESSURE

1. Release fuel pressure to zero. Refer to EC-SR-31. 2. Install fuel pressure gauge and check fuel pressure. At idling: When fuel pressure regulator valve vacuum hose is connected. Approximately 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43 psi) OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-221

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit (Refer to EC-SR-316.) I Fuel pressure regulator (Refer to EC-SR-32.) ©

5

Repair or replace.

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK

©

GO TO 6.

NG

©

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-123.

6

CHECK FUNCTION OF INJECTORS

With CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

4. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Install all parts removed. 2. Start engine. 3. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard. OK or NG OK

©

GO TO 7.

NG

©

Perform trouble diagnosis for “INJECTORS”, EC-SR-304.

EC-222

DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)

SR20DE

Diagnostic Procedure (Cont’d)

7

REMOVE INJECTOR

1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 2. Turn ignition switch “OFF”. 3. Remove injector assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery.

©

8 1. 2. 3. 4.

GO TO 8.

CHECK INJECTOR Disconnect all injector harness connectors. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injectors. Crank engine for about 3 seconds. Make sure fuel does not drip from injector. OK or NG

OK (Does not drip)

©

GO TO 9.

NG (Drips)

©

Replace the injectors from which fuel is dripping. Always replace O-ring with new one.

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-223

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

SR20DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0202

If a misfire occurs, the engine speed will fluctuate. If the fluctuation is detected by the crankshaft position sensor (OBD), the misfire is diagnosed. Sensor

Input Signal to ECM

Crankshaft position sensor (OBD)

ECM function

Engine speed

On board diagnosis of misfire

The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink. When a misfire condition occurs, the ECM monitors the CKP sensor signal every 200 engine revolutions for a change. When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink. When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on. If another misfire condition occurs that can damage the TWC, the MI will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect exhaust vehicle emissions), the MI will only light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor signal every 1,000 engine revolutions. A misfire malfunction can be detected on any one cylinder or on multiple cylinders. DTC No. P0300 0300 P0301 0301 P0302 0302 P0303 0303 P0304 0304

Malfunction is detected when ... I Multiple cylinders misfire. I No. 1 cylinder misfires. I No. 2 cylinder misfires. I No. 3 cylinder misfires.

I I I I I I I I I I I

I No. 4 cylinder misfires.

Check Items (Possible Cause) Improper spark plug Insufficient compression Incorrect fuel pressure The injector circuit is open or shorted Injectors Intake air leak The ignition secondary circuit is open or shorted Lack of fuel Heated oxygen sensor 1 (front) Drive plate/Flywheel Incorrect distributor rotor

DTC Confirmation Procedure

NEF068A

NCEC0203

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: I Always perform at a temperature above −10°C (14°F). With CONSULT-II 1) Turn ignition switch “ON”, and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch “OFF” and wait at least 9 seconds. 4) Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes. Hold the accelerator pedal as steady as possible. NOTE: Refer to the freeze frame data for the test driving conditions. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-SR-225. With GST Follow the procedure “With CONSULT-II” above.

EC-224

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0204

CHECK FOR INTAKE AIR LEAK

1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. OK or NG OK

©

GO TO 2.

NG

©

Discover air leak location and repair.

2

CHECK FOR EXHAUST SYSTEM CLOGGING

Stop engine and visually check exhaust tube, three way catalyst and muffler for dents. OK or NG OK

©

GO TO 3.

NG

©

Repair or replace it.

3

PERFORM POWER BALANCE TEST

With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.

NEF105A

2. Is there any cylinder which does not produce a momentary engine speed drop? Without CONSULT-II When disconnecting each injector harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? Remove to test other injectors

Injector harness connector (for No. 2 cylinder)

Yes or No Yes

©

GO TO 5.

No

©

GO TO 8.

EC-225

SEF233X

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

SR20DE

Diagnostic Procedure (Cont’d)

4

CHECK INJECTOR

Does each injector make an operating sound at idle?

MEC703B

Yes or No Yes

©

GO TO 6.

No

©

Check injector(s) and circuit(s). Refer to EC-SR-304.

5 1. 2. 3. 4. 5.

CHECK IGNITION SPARK Turn Ignition switch “OFF”. Disconnect ignition wire from spark plug. Connect a known good spark plug to the ignition wire. Place end of spark plug against a suitable ground and crank engine. Check for spark.

Ignition wire

Spark plug

SEF282G

OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

6

CHECK IGNITION WIRES

Refer to “Component Inspection”, EC-SR-229. OK or NG OK

©

Check distributor rotor head for incorrect parts. Check ignition coil, power transistor and their circuits. Refer to EC-SR-310.

NG

©

Replace.

EC-226

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

SR20DE

Diagnostic Procedure (Cont’d)

7

CHECK SPARK PLUGS

Remove the spark plugs and check for fouling, etc.

SEF156I

OK or NG OK

©

GO TO 9.

NG

©

Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to “ENGINE MAINTENANCE” in MA section.

8

CHECK COMPRESSION PRESSURE

Refer to EM section. I Check compression pressure. Standard: 1,226 kPa (12.26 bar, 12.5 kg/cm2, 178 psi)/300 rpm Minimum: 1,030 kPa (10.30 bar, 10.5 kg/cm2, 149 psi)/300 rpm Difference between each cylinder: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)/300 rpm OK or NG OK

©

GO TO 10.

NG

©

Check pistons, piston rings, valves, valve seats and cylinder head gaskets.

9

CHECK FUEL PRESSURE

1. Install any parts removed. 2. Release fuel pressure to zero. Refer to EC-SR-31. 3. Install fuel pressure gauge and check fuel pressure.

Fuel filter

SEF194X

At idle: Approx. 235 kPa (2.35 bar, 2.4 kg/cm2, 34 psi) OK or NG OK

©

GO TO 12.

NG

©

GO TO 11.

EC-227

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE Diagnostic Procedure (Cont’d)

10

DETECT MALFUNCTIONING PART

Check the following. I Fuel pump and circuit Refer to EC-SR-320. I Fuel pressure regulator Refer to EC-SR-32. I Fuel lines Refer to “ENGINE MAINTENANCE” in MA section. I Fuel filter for clogging

©

11

Repair or replace.

CHECK IGNITION TIMING

Perform “Basic Inspection”, EC-SR-84. OK or NG OK

©

GO TO 13.

NG

©

Adjust ignition timing.

12

CHECK HEATED OXYGEN SENSOR 1 (FRONT)

Refer to “Component Inspection”, EC-SR-154. OK or NG OK

©

GO TO 14.

NG

©

Replace heated oxygen sensor 1 (front).

13

CHECK MASS AIR FLOW SENSOR

With CONSULT-II Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec With GST Check mass air flow sensor signal in MODE 1 with GST. at idling: 2.5 - 5.0 g⋅m/sec at 2,500 rpm: 7.1 - 12.5 g⋅m/sec OK or NG OK

©

GO TO 16.

NG

©

GO TO 15.

14

CHECK CONNECTORS

Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-SR-120. OK or NG NG

15

©

Repair or replace it.

CHECK SYMPTOM MATRIX CHART

Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-SR-94. OK or NG OK

©

GO TO 17.

NG

©

Repair or replace.

EC-228

SR20DE

DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE

SR20DE Component Inspection

16

ERASE THE 1ST TRIP DTC

Some tests may cause a 1st trip DTC to be set. Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-SR-56.

©

17

GO TO 18.

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection IGNITION WIRES 1. 2.

SEF174P

NCEC0576 NCEC0576S01

Inspect wires for cracks, damage, burned terminals and for improper fit. Measure the resistance of wires to their distributor cap terminal. Move each wire while testing to check for intermittent breaks. Resistance: 4.5 - 6.7 kΩ/m (1.37 - 2.04 kΩ/ft) at 25°C (77°F) If the resistance exceeds the above specification, inspect ignition wire to distributor cap connection. Clean connection or replace the ignition wire with a new one.

EC-229

SR20DE

DTC P0325 KNOCK SENSOR (KS) Component Description

Component Description

NCEC0206

The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. Freeze frame data will not be stored in the ECM for the knock sensor. The MI will not light for knock sensor malfunction. The knock sensor has one trip detection logic. SEF598K

ECM Terminals and Reference Value

NCEC0207

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 81

WIRE COLOR W

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Idle speed

Knock sensor

2.0 - 3.0V

On Board Diagnosis Logic DTC No. P0325 0325

Malfunction is detected when ... I An excessively low or high voltage from the knock sensor is sent to ECM.

Check Items (Possible Cause) I Harness or connectors (The knock sensor circuit is open or shorted.) I Knock sensor

DTC Confirmation Procedure

NEF068A

NCEC0208

NCEC0209

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 5 seconds at idle speed. 3) If DTC is detected, go to “Diagnostic Procedure”, EC-SR-232. With GST Follow the procedure “With CONSULT-II” above.

EC-230

DTC P0325 KNOCK SENSOR (KS)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0210

YEC089A

EC-231

DTC P0325 KNOCK SENSOR (KS)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0211

RETIGHTEN GROUND SCREWS

Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT-1

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and knock sensor harness connector. View from under the vehicle Knock sensor harness connector

Knock sensor

Drive shaft

SEF210X

3. Check harness continuity between knock sensor signal terminal 2 and ECM terminal 81. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between knock sensor and ECM.

©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK KNOCK SENSOR

Knock sensor Refer to “Component Inspection”, EC-SR-233. OK or NG OK

©

GO TO 5.

NG

©

Replace knock sensor.

EC-232

DTC P0325 KNOCK SENSOR (KS)

SR20DE Component Inspection

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection KNOCK SENSOR I 1. 2.

NCEC0212 NCEC0212S01

Use an ohmmeter which can measure more than 10 MΩ. Disconnect knock sensor harness connector. Check resistance between terminal 2 and ground. Resistance: 532 - 588 kΩ [at 20°C (68°F)] CAUTION: Discard any knock sensors that have been dropped or physically damaged. Use only new ones.

SEF057X

EC-233

DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Component Description

Component Description Core

Coil Permanent magnet SEF956N

NCEC0577

The crankshaft position sensor (OBD) is located on the transmission housing facing the gear teeth (cogs) of the flywheel or drive plate. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet, core and coil. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. This sensor is not used to control the engine system. It is used only for the on board diagnosis.

Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)

SEF226X

ECM Terminals and Reference Value

NCEC0578

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58

WIRE COLOR

B

ITEM

Sensors’ ground

CONDITION

DATA (AC Voltage)

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V 3 - 5V (AC range)

[Engine is running] I Warm-up condition I Idle speed SEF721W

65

W

Crankshaft position sensor (OBD)

6 - 9V (AC range)

[Engine is running] I Engine speed is 2,000 rpm SEF722W

On Board Diagnosis Logic DTC No. P0335 0335

Malfunction is detected when ...

NCEC0579

Check Items (Possible Cause)

I The proper pulse signal from the crankshaft position sen- I Harness or connectors sor (OBD) is not sent to ECM while the engine is running (The crankshaft position sensor (OBD) circuit is at the specified engine speed. open.) I Crankshaft position sensor (OBD)

EC-234

DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE DTC Confirmation Procedure

DTC Confirmation Procedure

NCEC0580

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 10 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-237. With GST Follow the procedure “With CONSULT-II” above.

EC-235

DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Wiring Diagram

Wiring Diagram

NCEC0581

: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models CRANKSHAFT POSITION SENSOR (OBD)

TCM (TRANSMISSION CONTROL MODULE)

ECM

YEC839

EC-236

DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0582

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)

SEF226X

2. Check continuity between ECM terminal 65 and crankshaft position sensor (OBD) harness connector terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between crankshaft position sensor (OBD) and ECM.

©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Reconnect ECM harness connectors. 2. Check harness continuity between crankshaft position sensor harness connector terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between crankshaft position sensor (OBD) and ECM I Harness for open or short between crankshaft position sensor (OBD) and TCM (Transmission control module)

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-237

DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) SR20DE Component Inspection

6

CHECK IMPROPER INSTALLATION

Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). Then retest.

Trouble is not fixed.

7

©

GO TO 7.

CHECK CRANKSHAFT POSITION SENSOR (OBD)

Refer to “Component Inspection”, EC-SR-238. OK or NG OK

©

GO TO 8.

NG

©

Replace crankshaft position sensor (OBD).

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection CRANKSHAFT POSITION SENSOR (OBD) 1. 2. 3. 4.

Disconnect crankshaft position sensor (OBD) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.

SEF960N

5.

NCEC0583 NCEC0583S01

Check resistance as shown in the figure. Resistance: M/T models 166 - 204 Ω [at 20°C (68°F)] CVT models Approx. 285 Ω [at 20°C (68°F)]

SEF231W

EC-238

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE

Component Description Rotor head Sealed cover

Light emitting diode

Photo diode

Ignition coil with power transistor SEF998R

180° signal slit for No. 1 cylinder 1° signal slit 180° signal slit

Component Description

NCEC0220

The camshaft position sensor is a basic component of the engine control system. It monitors engine speed and piston position. These input signals to the engine control system are used to control fuel injection, ignition timing and other functions. The camshaft position sensor has a rotor plate and a wave-forming circuit. The rotor plate has 360 slits for a 1° (POS) signal and 4 slits for a 180° (REF) signal. The wave-forming circuit consists of Light Emitting Diodes (LED) and photo diodes. The rotor plate is positioned between the LED and the photo diode. The LED transmits light to the photo diode. As the rotor plate turns, the slits cut the light to generate rough-shaped pulses. These pulses are converted into on-off signals by the wave-forming circuit and sent to the ECM. The distributor is not repairable and must be replaced as an assembly except distributor cap and rotor head.

SEF853B

Rotor plate

ECM Terminals and Reference Value

NCEC0221

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) 0.1 - 0.4V

66*1

[Engine is running] I Warm-up condition I Idle speed

L

SEF006W

Camshaft position sensor (Reference signal)

75

L

0.1 - 0.4V

[Engine is running] I Engine speed is 2,000 rpm

SEF007W

*1: Models before VIN - P11U0548750

EC-239

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE

ECM Terminals and Reference Value (Cont’d) TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 2.5V

[Engine is running] I Warm-up condition I Idle speed 0.2 ms SEF004W

85

Camshaft position sensor (Position signal)

B/W

Approximately 2.4V

[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF005W

On Board Diagnosis Logic DTC No. P0340 0340

Malfunction is detected when ... A)

Either 1° or 180° signal is not sent to ECM for the first few seconds during engine cranking.

B)

Either 1° or 180° signal is not sent to ECM often enough while the engine speed is higher than the specified engine speed.

C)

The relation between 1° and 180° signal is not in the normal range during the specified engine speed.

NCEC0222

Check Items (Possible Cause) I Harness or connectors (The camshaft position sensor circuit is open or shorted.) I Camshaft position sensor I Starter motor (Refer to EL section.) I Starting system circuit (Refer to EL section.) I Dead (Weak) battery

DTC Confirmation Procedure

NCEC0223

Perform “Procedure for malfunction A” first. If DTC cannot be confirmed, perform “Procedure for malfunction B and C”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V.

PROCEDURE FOR MALFUNCTION A

NCEC0223S01

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Crank engine for at least 2 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-243. With GST Follow the procedure “With CONSULT-II” above. NEF068A

EC-240

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE

DTC Confirmation Procedure (Cont’d)

PROCEDURE FOR MALFUNCTION B AND C

NCEC0223S02

With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and run it for at least 2 seconds at idle speed. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-243. With GST Follow the procedure “With CONSULT-II” above. NEF068A

EC-241

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0224

YEC090A

EC-242

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0225

CHECK STARTING SYSTEM

Does the engine turn over? (Does the starter motor operate?) Yes or No Yes

©

GO TO 2.

No

©

Check starting system. (Refer to EL section.)

2

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. Intake manifold collector

Engine ground SEF202X

©

3

GO TO 3.

CHECK POWER SUPPLY

1. Disconnect camshaft position sensor harness connector. Ignition coil harness connector

Camshaft position sensor and power transistor harness connector

Distributor SEF211X

2. Turn ignition switch “ON”. 3. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF232W

Voltage: Battery voltage OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-243

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

SR20DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between camshaft position sensor and ECM relay I Harness for open or short between camshaft position sensor and ECM

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between sensor terminal 3 and ECM terminal 85, sensor terminal 4 and ECM terminals 66 (Models before VIN-P11U0548750), 75. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Check harness continuity between sensor terminal 1 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 7.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

7

CHECK CAMSHAFT POSITION SENSOR

Refer to “Component Inspection”, EC-SR-245. OK or NG OK

©

GO TO 8.

NG

©

Replace camshaft position sensor.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-244

SR20DE

DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)

Component Inspection

Component Inspection

NCEC0226

CAMSHAFT POSITION SENSOR

NCEC0226S01

1. 2.

Start engine and warm it up to normal operating temperature. Check voltage between ECM terminals 75, 85 and engine ground under the following conditions. Terminal 66 (or 75) and engine ground

SEF215X

Condition

Idle

2,000 rpm

Voltage

0.1 - 0.4V

0.1 - 0.4V

Pulse signal

SEF007W

SEF006W

Terminal 85 and engine ground Condition

Idle

2,000 rpm

Voltage

Approximately 2.5V

Approximately 2.4V

Pulse signal 0.2 ms

0.2 ms SEF004W

SEF005W

If NG, replace distributor assembly with camshaft position sensor.

EC-245

DTC P0420 THREE WAY CATALYST FUNCTION

SR20DE

On Board Diagnosis Logic

On Board Diagnosis Logic

NCEC0240

The ECM monitors the switching frequency ratio of front and heated oxygen sensor 2 (rear)s. A three way catalyst with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2 (rear). As oxygen storage capacity decreases, the heated oxygen sensor 2 (rear) switching frequency will increase. When the frequency ratio of front and heated oxygen sensor 2 (rear)s approaches a specified limit value, the three way catalyst malfunction is diagnosed. SEF184UD

DTC No. P0420 0420

Malfunction is detected when ... I Three way catalyst does not operate properly. I Three way catalyst does not have enough oxygen storage capacity.

Check Items (Possible Cause) I I I I I I I

Three way catalyst Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing

DTC Confirmation Procedure

NCEC0241

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

WITH CONSULT-II NEF247A

NEF248A

TESTING CONDITION: I Open engine hood before conducting the following procedure. I Do not hold engine speed for more than the specified minutes below. 1) Turn ignition switch “ON”. 2) Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 3) Start engine. 4) Rev engine up to 3,000±500 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. 5) Wait 5 seconds at idle. 6) Rev engine up to 2,500±500 rpm and maintain it until “INCMP” of CATALYST changes to “CMPLT” (It will take approximately 5 minutes). If not “CMPLT”, stop engine and cool it down to less than 70°C (158°F) and then retest from step 1. 7) Select “SELF-DIAG RESULTS” mode with CONSULT-II. 8) Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-SR-247.

SEF560X

EC-246

DTC P0420 THREE WAY CATALYST FUNCTION

SR20DE Overall Function Check

Overall Function Check

SEF074X

Diagnostic Procedure 1

NCEC0242

Use this procedure to check the overall function of the three way catalyst. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and drive vehicle at a speed of more than 70 km/h (43 MPH) for 2 consecutive minutes. 2) Stop vehicle with engine running. 3) Set voltmeters probes between ECM terminals 62 (Heated oxygen sensor 1 (front) signal), 63 (Heated oxygen sensor 2 (rear) signal) and engine ground. 4) Keep engine speed at 2,000 rpm constant under no load. 5) Make sure that the voltage switching frequency (high & low) between ECM terminal 63 and engine ground is much less than that of ECM terminal 62 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 (rear) voltage switching frequency B: Heated oxygen sensor 1 (front) voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means three way catalyst does not operate properly. NOTE: If the voltage at terminal 62 does not switch periodically more than 5 times within 10 seconds at step 4, perform trouble diagnosis for DTC P0133 first. (See EC-SR-163.)

CHECK EXHAUST SYSTEM

Visually check exhaust tubes and muffler for dent. OK or NG OK

©

GO TO 2.

NG

©

Repair or replace.

EC-247

NCEC0243

DTC P0420 THREE WAY CATALYST FUNCTION

SR20DE

Diagnostic Procedure (Cont’d)

2

CHECK EXHAUST AIR LEAK

1. Start engine and run it at idle. 2. Listen for an exhaust air leak before the three way catalyst.

SEF099P

OK or NG OK

©

GO TO 3.

NG

©

Repair or replace.

3

CHECK INTAKE AIR LEAK

Listen for an intake air leak after the mass air flow sensor. OK or NG OK

©

GO TO 4.

NG

©

Repair or replace.

4

CHECK IGNITION TIMING

Check for ignition timing. Refer to TROUBLE DIAGNOSIS — “BASIC INSPECTION”, EC-SR-84. OK or NG OK

©

GO TO 5.

NG

©

Adjust ignition timing.

5

CHECK INJECTORS

1. Refer to Wiring Diagram for Injectors, EC-SR-304. 2. Stop engine and then turn ignition switch “ON”. 3. Check voltage between ECM terminals 101, 103, 105 and 107 and ground with CONSULT-II or tester.

SEF075X

Battery voltage should exist. OK or NG OK

©

GO TO 6.

NG

©

Perform “Diagnostic Procedure” INJECTOR, EC-SR-304.

EC-248

DTC P0420 THREE WAY CATALYST FUNCTION

SR20DE

Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK IGNITION SPARK Disconnect ignition wire from spark plug. Connect a known good spark plug to the ignition wire. Place end of spark plug against a suitable ground and crank engine. Check for spark.

Ignition wire

Spark plug

SEF282G

OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

CHECK IGNITION WIRES

Refer to “Component Inspection”, EC-SR-310. OK or NG OK

©

Check ignition coil, power transistor and their circuits. Refer to EC-SR-310.

NG

©

Replace.

8

CHECK INJECTOR

1. Turn ignition switch “OFF”. 2. Remove injector assembly. Refer to EC-SR-32. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect camshaft position sensor harness connector. 4. Turn ignition switch “ON”. Make sure fuel does not drip from injector. OK or NG OK (Does not drip)

©

GO TO 9.

NG (Drips)

©

Replace the injector(s) from which fuel is dripping.

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

Trouble is fixed

©

INSPECTION END

Trouble is not fixed

©

Replace three way catalyst.

EC-249

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)

SR20DE

Description

Description

NCEC0248

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Crankshaft position sensor (POS)

Engine speed

Mass air flow sensor

Amount of intake air

Engine coolant temperature sensor

Engine coolant temperature

Battery

Battery voltage

Ignition switch

Start signal

Closed throttle position switch

Closed throttle position

Throttle position sensor

Throttle position

Heated oxygen sensor 1 (front)

Density of oxygen in exhaust gas (Mixture ratio feedback signal)

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

NCEC0248S01

ECM function

EVAP canister purge control

Actuator

EVAP canister purge volume control solenoid valve

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes.

COMPONENT DESCRIPTION

NCEC0248S02

The EVAP canister purge volume control solenoid valve uses a ON/OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve.

SEF337U

CONSULT-II Reference Value in Data Monitor Mode

NCEC0249

MONITOR ITEM PURG VOL C/V

CONDITION I Engine: Running

SPECIFICATION

Vehicle stopped

0%

Vehicle running

—

EC-250

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)

SR20DE

ECM Terminals and Reference Value

ECM Terminals and Reference Value

NCEC0250

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

BATTERY VOLTAGE (11 - 14V) 5 - 12V

14

P/B

EVAP canister purge volume control solenoid valve (ON/OFF duty)

[Engine is running] I Warm-up condition I 2,000 rpm SEF975W

On Board Diagnosis Logic DTC No. P0443 0443

Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.

NCEC0251

Check Items (Possible Cause) I Harness or connectors (The valve circuit is open or shorted.) I EVAP canister purge volume control solenoid valve

DTC Confirmation Procedure

NCEC0252

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 5 seconds. If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-253. With GST 1) Start engine and let it idle for at least 5 seconds. 2) Select “MODE 7” with GST. 3) If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-253. 1) 2) 3) 4)

SEF058Y

EC-251

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0253

IGNITION SWITCH ON or START FUSE BLOCK (J/B)

Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models

EVAP CANISTER PURGE CONTROL SOLENOID VALVE

.

ECM

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

YEC843

EC-252

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0254

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector. Harness connector

EVAP canister purge volume control solenoid valve

Oil filler cap

SEF219X

3. Turn ignition switch “ON”. 4. Check voltage between terminals 2 and engine ground with CONSULT-II or tester.

DISCONNECT

SEF077X

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness connectors M50, F104 (M81, F115 for CVT models).

©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 14 and terminal 1. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-253

DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)

SR20DE

Component Inspection

4

CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

Refer to “Component Inspection” EC-SR-254. OK or NG OK

©

GO TO 5.

NG

©

Replace EVAP canister purge volume control solenoid valve.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection

NCEC0255

EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE

NEF111A

NCEC0255S01

With CONSULT-II 1) Start engine. 2) Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. If OK, inspection end. If NG, go to following step. 3) Check air passage continuity. Condition PURG VOL CONT/V value

Air passage continuity between A and B

100.0%

Yes

0.0%

No

If NG, replace the EVAP canister purge volume control solenoid valve. Without CONSULT-II Check air passage continuity. SEF079X

Condition

Air passage continuity between A and B

12V direct current supply between terminals

Yes

No supply

No

If NG or operation takes more than 1 second, replace solenoid valve.

EC-254

SR20DE

DTC P0500 VEHICLE SPEED SENSOR (VSS)

Component Description

Component Description

NCEC0272

MODELS WITH VEHICLE SPEED SENSOR The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.

MODELS WITHOUT VEHICLE SPEED SENSOR The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM. SEF080X

ECM Terminals and Reference Value

NCEC0273

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

WIRE COLOR

ITEM

CONDITION

DATA (DC Voltage) Approximately 2.5V

86

OR/W

[Engine is running] Vehicle speed sensor or I Lift up the vehicle ABS actuator and electric I In 2nd gear position unit (control unit) I Vehicle speed is 40 km/h (25 MPH) SEF976W

On Board Diagnosis Logic DTC No. P0500 0500

Malfunction is detected when ... I The almost 0 km/h (0 MPH) signal from vehicle speed sensor or ABS actuator and electric unit (control unit) is sent to ECM even when vehicle is being driven.

NCEC0274

Check Items (Possible Cause) Models with vehicle speed sensor I Harness or connector (The vehicle speed sensor circuit is open or shorted.) I Vehicle speed sensor Models without vehicle speed sensor I Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) I ABS actuator and electric unit (control unit)

DTC Confirmation Procedure

NCEC0275

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. TESTING CONDITION: This procedure may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle.

EC-255

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE

DTC Confirmation Procedure (Cont’d)

1) 2)

3)

NEF112A

4) 5) 6)

With CONSULT-II Start engine Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-SR-260. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 10 consecutive seconds.

ENG SPEED

2,000 - 3,000 rpm (CVT) 2,700 - 3,000 rpm (M/T)

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

5 - 8.5 msec (CVT) 5 - 14.5 msec (M/T)

Selector lever

Suitable position

PW/ST SIGNAL

OFF

7)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-260. With GST Follow the procedure “With CONSULT-II” above.

EC-256

SR20DE

DTC P0500 VEHICLE SPEED SENSOR (VSS)

Wiring Diagram

Wiring Diagram

NCEC0277

MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START

BATTERY

: Detectable line for DTC FUSE BLOCK (J/B)

Refer to EL-POWER.

: Non-detectable line for DTC : Hyper CVT models : M/T models

COMBINATION METER (SPEEDOMETER)

VEHICLE SPEED SENSOR

ECM

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

YEC844

EC-257

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE

Wiring Diagram (Cont’d)

MT MODELS WITH ABS AFTER VIN - P11U0548750

YEC091A

EC-258

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE Wiring Diagram (Cont’d)

EXCEPT MT MODELS WITH ABS AFTER VIN - P11U0548750

YEC092A

EC-259

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE

Diagnostic Procedure

Diagnostic Procedure

NCEC0278

MODELS BEFORE VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 9. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 and M52, F103 (CVT: M81, F115 and M80, F114) I Harness for open or short between combination meter and vehicle speed sensor

©

5

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-260

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE

Diagnostic Procedure (Cont’d)

MT MODELS WITH ABS AFTER VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 I Harness for open or short between combination meter and vehicle speed sensor

©

5

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-261

DTC P0500 VEHICLE SPEED SENSOR (VSS)

SR20DE

Diagnostic Procedure (Cont’d)

EXCEPT MT MODELS WITH ABS AFTER VIN - P11U0548750 1

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM terminal 86 and meter terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F104, M50 (CVT: F115, M81) I Harness for open or short between ECM and combination meter

©

3

Repair open circuit or short to ground or short to power in harness or connectors. Check Audio circuit and other linked circuit for short to ground or short to power power. Refer to EL section.

CHECK SPEEDOMETER FUNCTION

Make sure that speedometer functions properly. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M80, F114 and M81, F115 I Harness for open or short between combination meter and vehicle speed sensor

©

5

Repair harness or connectors. Check vehicle speed sensor and its circuit. Refer to EL section.

CHECK INTERMITTENT INCIDENT

Check combination meter internal circuit for short to ground or short to power. Refer to EL section. Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-262

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE Description

Description

NCEC0279

SYSTEM DESCRIPTION Sensor

Input Signal to ECM

Camshaft position sensor

Engine speed

Engine coolant temperature sensor

Engine coolant temperature

Ignition switch

Start signal

Throttle position sensor

Throttle position

PNP switch

Park/Neutral position

Air conditioner switch

Air conditioner operation

Power steering oil pressure switch

Power steering load signal

Battery

Battery voltage

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Cooling fan

Cooling fan operation

Electrical load

Electrical load signal

NCEC0279S01

ECM function

ECM

Actuator

IACV-AAC valve

This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve changes the opening of the air by-pass passage to control the amount of auxiliary air. This valve is actuated by a step motor built into the valve, which moves the valve in the axial direction in steps corresponding to the ECM output signals. One step of IACV-AAC valve movement causes the respective opening of the air by-pass passage. (i.e. when the step advances, the opening is enlarged.) The opening of the valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM then controls the step position of the IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warm up, deceleration, and engine load (air conditioner, power steering, cooling fan operation and electrical load).

COMPONENT DESCRIPTION

NCEC0279S02

The IACV-AAC valve is operated by a step motor for centralized control of auxiliary air supply. This motor has four winding phases and is actuated by the output signals of ECM which turns ON and OFF two windings each in sequence. Each time the IACV-AAC valve opens or closes to change the auxiliary air quantity, the ECM sends a pulse signal to the step motor. When no change in the auxiliary air quantity is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening. SEF937W

EC-263

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0280

MONITOR ITEM

CONDITION I I I I

IACV-AAC/V

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” or “P” No-load

SPECIFICATION

Idle

5 - 20 steps

2,000 rpm

—

ECM Terminals and Reference Value

NCEC0281

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 6 7 15 16

WIRE COLOR BR Y/B P OR

ITEM

CONDITION

DATA (DC Voltage)

[Engine is running] I Warm-up condition I Idle speed

IACV-AAC valve

0 - 14V

On Board Diagnosis Logic DTC No. P0505 0505

Malfunction is detected when ... I An improper voltage signal is sent to ECM through the valve.

Check Items (Possible Cause) I Harness or connectors (The IACV-AAC valve circuit is open.) I IACV-AAC valve

DTC Confirmation Procedure

NEF085A

NCEC0282

NCEC0283

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. If the target idle speed is out of the specified value, perform “Idle Air Volume Learning” EC-SR-46, before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to the “Service Data and Specifications (SDS)”, EC-SR-330. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and warm it up to normal operating temperature. 4) Rev engine from idle to more than 2,000 rpm 20 times. If 1st trip DTC is detected, go to “DIAGNOSTIC PROCEDURE”, EC-SR-266. With GST Follow the procedure “With CONSULT-II” above.

EC-264

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE Wiring Diagram

Wiring Diagram

NCEC0284

BATTERY : Detectable line for DTC : Non-detectable line for DTC

Refer to EL-POWER.

IACV-AAC VALVE

ECM RELAY

ECM

YEC845

EC-265

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0285

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect IACV-AAC valve harness connector.

IACV-AAC valve harness connector

SEF221X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 2, 5 and ground with CONSULT-II or tester.

SEF352QA

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F73, E90 I Harness for open or short between IACV-AAC and ECM relay I 10A fuse

©

3

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 6 and terminal 1, ECM terminal 7 and terminal 4, ECM terminal 15 and terminal 3, ECM terminal 16 and terminal 6. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-266

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

Diagnostic Procedure (Cont’d)

4 1. 2. 3. 4.

CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-I Reconnect the ECM harness connector and IACV-AAC valve harness connector. Disconnect vacuum hose connected to air control valve (Power steering) at intake air duct. Start and let it idle. Check vacuum hose for vacuum existence.

SEF969X

Vacuum slightly exists or does not exist. OK or NG OK

©

GO TO 5.

NG

©

Replace air control valve (Power steering).

5

CHECK AIR CONTROL VALVE (POWER STEERING) OPERATION-II

Check the vacuum hose for vacuum existence when steering wheel is turned.

SEF969X

Vacuum should exist. OK or NG OK

©

GO TO 8.

NG

©

GO TO 6.

EC-267

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

Diagnostic Procedure (Cont’d)

6 1. 2. 3. 4.

CHECK VACUUM PORT Stop engine. Disconnect vacuum hose connected to air control valve (Power steering) at the vacuum port. Blow air into vacuum port. Check that air flows freely.

SEF970X

OK or NG OK

©

GO TO 7.

NG

©

Repair or clean vacuum port.

7

CHECK VACUUM HOSES AND TUBES

1. Disconnect vacuum hoses between air control valve (Power steering) and vacuum port, air control valve (Power steering) and intake air duct. 2. Check hoses and tubes for cracks, clogging, improper connection or disconnection.

SEF109L

OK or NG OK

©

GO TO 8.

NG

©

Repair hoses or tubes.

EC-268

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

Diagnostic Procedure (Cont’d)

8

CHECK IACV-AAC VALVE

Refer to “Component Inspection”, EC-SR-270. OK or NG OK

©

GO TO 9.

NG

©

Replace IACV-AAC valve.

9

REPLACE IACV-AAC VALVE

1. Replace IACV-AAC valve assembly. 2. Perform “Idle Air Volume Learning”, EC-46. Is the result CMPLT or INCMP? CMPLT or INCMP CMPLT

©

INSPECTION END

INCMP

©

Follow the construction of “Idle Air Volume Learning”.

10

CHECK TARGET IDLE SPEED

1. Turn ignition switch “OFF”. 2. Reconnect all harness connectors and vacuum hoses. 3. Start engine and warm it up to normal operating temperature. 4. Also warm up transmission to normal operating temperature I For CVT models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “CVT” system indicates less than 0.9V. I For CVT models without CONSULT-II and M/T models, drive vehicle for 10 minutes. 5. Stop vehicle with engine running. 6. Check target idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) OK or NG OK

©

GO TO 11.

NG

©

Perform “Idle Air Volume Learning”, EC-45.

11

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-269

DTC P0505 IDLE AIR CONTROL VALVE (IACV) — AUXILIARY AIR CONTROL (AAC) VALVE

SR20DE

Component Inspection

Component Inspection

NCEC0286

IACV-AAC VALVE 1) 2)

NCEC0286S01

Disconnect IACV-AAC valve harness connector. Check IACV-AAC valve resistance. Condition

Resistance

Terminal 2 and terminals 1, 3 20 - 24Ω [at 20°C (68°F)] Terminal 5 and terminals 4, 6

3) 4)

5)

Reconnect IACV-AAC valve harness connector. Remove idle air adjusting unit assembly (IACV-AAC valve is built-in) from engine. (The IACV-AAC valve harness connector should remain connected.) Turn ignition switch “ON” and “OFF”, and ensure the IACVAAC valve shaft smoothly moves forward and backward, according to the ignition switch position. If NG, replace the IACV-AAC valve.

SEF353QA

SEF089X

EC-270

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE

Component Description

Component Description

Throttle position switch built into throttle position sensor

NCEC0287

A closed throttle position switch and wide open throttle position switch are built into the throttle position sensor unit. The wide open throttle position switch is used only for CVT control. When the throttle valve is in the closed position, the closed throttle position switch sends a voltage signal to the ECM. The ECM only uses this signal to open or close the EVAP canister purge control valve when the throttle position sensor is malfunctioning.

Throttle position switch connector

Throttle position sensor connector

SEF505V

CONSULT-II Reference Value in Data Monitor Mode

NFEC0257

Specification data are reference values. MONITOR ITEM CLSD THL/P SE

CONDITION I Engine: Idle

SPECIFICATION

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

ECM Terminals and Reference Value

NCEC0288

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERWIRE MINAL COLOR NO.

40

Y

ITEM

Throttle position switch (Closed position)

CONDITION

DATA (DC Voltage)

[Engine is running] I Accelerator pedal released

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”] I Accelerator pedal depressed

Approximately 0V

On Board Diagnosis Logic DTC No. P0510 0510

Malfunction is detected when ...

Check Items (Possible Cause)

I Battery voltage from the closed throttle position switch is I Harness or connectors sent to ECM with the throttle valve opened. (The closed throttle position switch circuit is shorted.) I Closed throttle position switch I Throttle position sensor

EC-271

NCEC0289

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

SEF092X

NCEC0290

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Check ignition switch “OFF”, wait at least 9 seconds and then start engine. 3) Select “CLSD THL/P SW” in “DATA MONITOR” mode. If “CLSD THL/P SW” is not available, go to step 5. 4) Check the signal under the following conditions. Condition

Signal indication

Throttle valve: Idle position

ON

Throttle valve: Slightly open

OFF

PEF329U

5) 6)

If the result is NG, go to “Diagnostic Procedure”, EC-SR-274. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Drive the vehicle for at least 5 consecutive seconds under the following condition.

THRTL POS SEN

More than 2.3V

VHCL SPEED SE

More than 4 km/h (2 MPH)

Selector lever

Suitable position

Driving pattern

Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test.

7)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-274.

Overall Function Check

CONNECT

NCEC0291

Use this procedure to check the overall function of the closed throttle position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Check the voltage between ECM terminal 40 (Closed throttle position switch signal) and ground under the following conditions. Condition

SEF090X

Voltage

At idle

Battery voltage

At 2,000 rpm

Approximately 0V

3)

If NG, go to “Diagnostic Procedure”, EC-SR-274.

EC-272

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE Wiring Diagram

Wiring Diagram

NCEC0292

BATTERY : Detectable line for DTC : Non-detectable line for DTC

Refer to EL-POWER.

ECM RELAY

WIDE OPEN

OFF

CLOSED

THROTTLE POSITION SWITCH (CLOSED THROTTLE POSITION SWITCH AND WIDE OPEN THROTTLE POSITION SWITCH

OFF

ECM

YEC846

EC-273

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0293

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect throttle position switch harness connector. Throttle position sensor harness connector

Throttle body

Closed throttle position switch harness connector

SEF197X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 5 and engine ground with CONSULT-II or tester.

SEF250W

Voltage: Battery voltage OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F73, E90 I Harness for open or short between throttle position switch and ECM relay I 10A fuse

©

3

Repair harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 40 and terminal 4. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-274

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between throttle position switch and ECM I Harness for open or short between throttle position switch and TCM (Transmission control module)

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

ADJUST THROTTLE POSITION SWITCH IDLE POSITION

Perform Basic Inspection, EC-SR-84.

©

6

GO TO 6.

CHECK CLOSED THROTTLE POSITION SWITCH

Refer to “Component Inspection”, EC-SR-276. OK or NG OK

©

GO TO 7.

NG

©

Replace throttle position switch.

7

CHECK THROTTLE POSITION SENSOR

Refer to “Component Inspection”, EC-SR-142. OK or NG OK

©

GO TO 8.

NG

©

Replace throttle position sensor.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-275

DTC P0510 CLOSED THROTTLE POSITION SWITCH (IF SO EQUIPPED)

SR20DE

Component Inspection

Component Inspection

NCEC0294

CLOSED THROTTLE POSITION SWITCH

NCEC0294S01

With CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Stop engine and turn ignition switch “ON”. 3) Select “DATA MONITOR” mode with CONSULT-II. 4) Check indication of “CLSD THL/P SW” under the following conditions. NOTE: Measurement must be made with closed throttle position switch installed in vehicle. Throttle valve conditions

CLSD THL/P SW

Completely closed

ON

Partially open or completely open

OFF

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-SR-84. 5) If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch. Without CONSULT-II 1) Start engine and warm it up to normal operating temperature. 2) Turn ignition switch “OFF”. 3) Disconnect throttle position switch harness connector. 4) Check continuity between terminals 4 and 5 under the following conditions. Refer to wiring diagram. NOTE: Continuity measurement must be made with closed throttle position switch installed in vehicle. Throttle valve conditions

Continuity

Completely closed

Yes

Partially open or completely open

No

5)

If NG, adjust closed throttle position switch. Refer to “Basic Inspection”, EC-SR-84. If it is impossible to adjust closed throttle position switch in “Basic Inspection”, replace closed throttle position switch.

EC-276

SR20DE

DTC P0605 ECM

Component Description

Component Description

NCEC0295

The ECM consists of a microcomputer, diagnostic test mode selector, and connectors for signal input and output and for power supply. The ECM controls the engine.

SEF093X

On Board Diagnosis Logic DTC No. P0605 0605

Malfunction is detected when ... I ECM calculation function is malfunctioning.

Check Items (Possible Cause) I ECM

DTC Confirmation Procedure

NEF068A

NCEC0296

NCEC0297

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine. 4) Run engine for at least 1 second at idle speed. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-278. With GST Follow the procedure “With CONSULT-II” above.

EC-277

DTC P0605 ECM

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

INSPECTION START

With CONSULT-II Turn ignition switch “ON”. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.

With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See previous page. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4.

Yes or No Yes

©

Replace ECM.

No

©

INSPECTION END

EC-278

=NCEC0298

SR20DE

DTC P1217 OVERHEAT (COOLING SYSTEM)

System Description

System Description

NCEC0433

COOLING FAN CONTROL

NCEC0433S01

Sensor

Input Signal to ECM

ECM function

Actuator

Vehicle speed sensor or ABS actuator and Vehicle speed electric unit (control unit) Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner “ON” signal

Ignition switch

Start signal

Refrigerant pressure sensor

Refrigerant pressure

ECM

Cooling fan relay(s)

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has ON-OFF control. The refrigerant pressure sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The transducer is installed in the liquid tank of the air conditioner system.

SEF099X

OPERATION

NCEC0433S02

Engine coolant temperature °C (°F)

Refrigerant pressure is less than 1.76 Mpa. 105 (221) 100 (212) 95 (203)

Engine coolant temperature °C (°F)

Engine coolant temperature °C (°F)

20 (12) 80 (50) Vehicle speed km/h (MPH) Refrigerant pressure is above 2.06 Mpa. Refrigerant pressure is between 1.76 Mpa and 2.06 Mpa. 105 (221) 100 (212) 95 (203)

105 (221) Cooling fans operate at “High” speed.

100 (212) 95 (203)

Cooling fans operate at “Low” speed. Cooling fans do no operate 20 (12) 80 (50) Vehicle speed km/h (MPH)

20 (12) 80 (50) Vehicle speed km/h (MPH)

EC-279

SEF198X

SR20DE

DTC P1217 OVERHEAT (COOLING SYSTEM) CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0486

Specification data are reference values. MONITOR ITEM

CONDITION I Engine: After warming up, idle the engine

AIR COND SIG

I After warming up engine, idle the engine. I Air conditioner switch: OFF

COOLING FAN

SPECIFICATION

Air conditioner switch: OFF

OFF

Air conditioner switch: ON (Compressor operates)

ON

Engine coolant temperature is 94°C (201°F) or less

OFF

Engine coolant temperature is between 95°C (203°F) and 104°C (219°F)

LOW

Engine coolant temperature is 105°C (221°F) or more

HIGH

ECM Terminals and Reference Value

NCEC0487

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

13

23

74

WIRE COLOR

LG/R

—

R/L

ITEM

Cooling fan relay

Air conditioner switch

Refrigerant pressure sensor

CONDITION

DATA (DC Voltage)

[Engine is running] I Cooling fan is not operating

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Cooling fan is operating

Approximately 0V

[Engine is running] I Both air conditioner switch and blower switch are “ON” (Compressor operates)

Approximately 0V

[Engine is running] I Air conditioner switch is “OFF”

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Idle speed I Air conditioner is “ON”

More than 1.5V

On Board Diagnosis Logic

NCE0488

If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. DTC No. P1217 1217

Malfunction is detected when ...

Check Items (Possible Cause)

I Cooling fan does not operate properly (Overheat). I Harness or connectors I Cooling fan system does not operate properly (Overheat). (The cooling fan circuit is open or shorted). I Engine coolant was not added to the system using the I Cooling fan I Radiator hose proper filling method. I Radiator I Radiator cap I Water pump I Thermostat For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-SR-288.

CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil. 1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-280

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE Overall Function Check

Overall Function Check

SEF621WA

SEF111X

SEC163BA

NCEC0489

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. With CONSULT-II 1) Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 3) Turn ignition switch “ON”. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. 5) If the results are NG, go to “Diagnostic Procedure”, EC-SR284. Without CONSULT-II 1) Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “Diagnostic Procedure”, EC-SR-284. 3) Start engine. Be careful not to overheat engine. 4) Set temperature control lever to full cold position. 5) Turn air conditioner switch “ON”. 6) Turn blower fan switch “ON”. 7) Run engine at idle for a few minutes with air conditioner operating. Be careful not to overheat engine. 8) Make sure that cooling fan operates. If NG, go to “Diagnostic Procedure”, EC-SR-284.

EC-281

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE

Wiring Diagram

Wiring Diagram IGNITION SWITCH ON or START

NCEC0490

BATTERY Detectable line for DTC Non-detectable line for DTC

FUSE BLOCK (J/B)

Refer to EL-POWER.

COOLING FAN RELAY

COOLING FAN MOTOR-1

COOLING FAN MOTOR-2

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

YEC847

EC-282

SR20DE

DTC P1217 OVERHEAT (COOLING SYSTEM)

Wiring Diagram (Cont’d)

: Detectable line for DTC REFRIGERANT SENSOR

: Non-detectable line for DTC : Hyper CVT models

TCM (TRANSMISSION CONTROL MODULE)

ECM

YEC848

EC-283

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5.

NCEC0491

CHECK COOLING FAN OPERATION Start engine and let it idle. Set temperature lever at full cold position. Turn air conditioner switch “ON”. Turn blower fan switch “ON”. Make sure that cooling fans-1 and -2 operate.

SEC163BA

OK or NG OK

©

GO TO 11.

NG

©

GO TO 2.

2

CHECK AIR CONDITIONER OPERATION

Is air conditioner operating? (Check operation of compressor and blower motor.) OK or NG OK

©

GO TO 3.

NG

©

Check for failure of air conditioner to operate. Refer to HA section.

3 1. 2. 3. 4.

CHECK POWER SUPPLY Turn ignition switch “OFF”. Disconnect cooling fan relay. Turn ignition switch “ON”. Check voltage between terminals 2, 3 and ground with CONSULT-II or tester.

SEF112X

Voltage: Battery voltage OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

EC-284

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE

Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M70, E125 I 10A fuse I 40A fusible link I Harness for open or short between cooling fan relay and fuse

©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect cooling fan motor-1 harness connector and cooling fan motor-2 harness connector. Right side (View from under the vehicle)

Left side

Cooling fan motor harness connector

SEF225X

3. Check harness continuity between relay terminal 5 and motor-1 terminal 1, motor-1 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. 5. Check harness continuity between relay terminal 5 and motor-2 terminal 1, motor-2 terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 6. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK OUTPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 13 and relay terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E42, F4 I Harness for open or short between cooling fan relay and ECM

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-285

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE

Diagnostic Procedure (Cont’d)

8

CHECK COOLING FAN RELAY

Refer to “Component Inspection”, EC-SR-289. OK or NG OK

©

GO TO 9.

NG

©

Replace cooling fan relay.

9

CHECK COOLING FAN MOTORS-1 AND -2

Refer to “Component Inspection”, EC-SR-289. OK or NG OK

©

GO TO 10.

NG

©

Replace cooling fan motors.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

11

INSPECTION END

CHECK COOLING SYSTEM FOR LEAK

Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage.

SLC754A

Pressure should not drop. OK or NG OK

©

GO TO 12.

NG

©

Check the following for leak I Hose I Radiator I Water pump Refer to LC section (“Water Pump”).

EC-286

DTC P1217 OVERHEAT (COOLING SYSTEM)

SR20DE

Diagnostic Procedure (Cont’d)

12

CHECK RADIATOR CAP

Apply pressure to cap with a tester.

SLC755A

Radiator cap relief pressure: 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK

©

GO TO 13.

NG

©

Replace radiator cap.

13

CHECK THERMOSTAT

1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift.

SLC343

Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). OK or NG OK

©

GO TO 14.

NG

©

Replace thermostat

14

CHECK ENGINE COOLANT TEMPERATURE SENSOR

Refer to “COMPONENT INSPECTION”, EC-SR-136. OK or NG OK

©

GO TO 15.

NG

©

Replace engine coolant temperature sensor.

15

CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-SR-288. ©

INSPECTION END

EC-287

SR20DE

DTC P1217 OVERHEAT (COOLING SYSTEM) Main 12 Causes of Overheating

Main 12 Causes of Overheating Engine

Step

Inspection item

OFF

1

I I I I

2

Equipment

Standard

NCEC0492

Reference page

I Visual

No blocking

I Coolant mixture

I Coolant tester

50 - 50% coolant mixture

3

I Coolant level

I Visual

Coolant up to MAX level in See “Changing Engine reservoir tank and radiator Coolant”, “ENGINE filler neck MAINTENANCE” in MA section.

4

I Radiator cap

I Pressure tester

59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 14 psi) (Limit)

See “System Check”, “ENGINE COOLING SYSTEM” in LC section.

ON*2

5

I Coolant leaks

I Visual

No leaks

See “System Check”, “ENGINE COOLING SYSTEM” in LC section.

ON*2

6

I Thermostat

I Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.

ON*1

7

I Cooling fan

I CONSULT-II

Operating

See “TROUBLE DIAGNOSIS FOR OVERHEAT” (EC-SR-279).

OFF

8

I Combustion gas leak

I Color checker chemical tester 4 Gas analyzer

Negative

—

ON*3

9

I Coolant temperature gauge

I Visual

Gauge less than 3/4 when driving

—

I Coolant overflow to reservoir tank

I Visual

No overflow during driving and idling

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section.

Blocked Blocked Blocked Blocked

radiator condenser radiator grille bumper

—

See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.

OFF*4

10

I Coolant return from reservoir tank to radiator

I Visual

Should be initial level in reservoir tank

See “ENGINE MAINTENANCE” in MA section.

OFF

11

I Cylinder head

I Straight gauge feeler gauge

0.1 mm (0.004 in) Maximum distortion (warping)

See “Inspection”, “CYLINDER HEAD” in EM section.

12

I Cylinder block and pistons

I Visual

No scuffing on cylinder walls or piston

See “Inspection”, “CYLINDER BLOCK” in EM section.

*1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.

EC-288

SR20DE

DTC P1217 OVERHEAT (COOLING SYSTEM)

Component Inspection

Component Inspection

NCEC0493

COOLING FAN RELAYS

NCEC0493S01

Check continuity between terminals 3 and 5.

SEF511P

Conditions

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

If NG, replace relay.

COOLING FAN MOTORS-1 AND -2 1. 2.

NCEC0493S02

Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. Terminals

Cooling fan motor SEF721Q

(+)

(−)

1

2

Cooling fan motor should operate. If NG, replace cooling fan motor.

REFRIGERANT PRESSURE SENSOR

NCEC0493S03

With the refrigerant pressure sensor installed on the vehicle, start the engine and while idling, read the voltage at refrigerant pressure sensor terminals 1 and 2. (Refer to wiring diagram.) Air conditioner condition

Voltage V

OFF

More than approx. 0.3V

ON

More than approx. 1.5

ON to OFF

Decreasing gradually

If results are NG, check for 5V between refrigerant sensor terminal 3 and ground. If there is 5V, replace sensor.

EC-289

DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)

SR20DE

Component Description

Component Description Core

Coil Permanent magnet SEF956N

NCEC0327

The crankshaft position sensor (OBD) is located on the transmission housing facing the gear teeth (cogs) of the flywheel or drive plate. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet, core and coil. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. This sensor is not used to control the engine system. It is used only for the on board diagnosis.

Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)

SEF226X

ECM Terminals and Reference Value

NCEC0328

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 58

WIRE COLOR

B

ITEM

Sensors’ ground

CONDITION

DATA (AC Voltage)

[Engine is running] I Warm-up condition I Idle speed

Approximately 0V 3 - 5V (AC range)

[Engine is running] I Warm-up condition I Idle speed 0.2 ms SEF721W

65

W

Crankshaft position sensor (OBD)

6 - 9V (AC range)

[Engine is running] I Engine speed is 2,000 rpm 0.2 ms SEF722W

On Board Diagnosis Logic DTC No. P1336 1336

Malfunction is detected when ...

Check Items (Possible Cause)

I A chipping of the flywheel or drive plate gear tooth (cog) I Harness or connectors is detected by the ECM. I Crankshaft position sensor (OBD) I Drive plate/Flywheel

EC-290

NCEC0329

DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)

SR20DE

DTC Confirmation Procedure

DTC Confirmation Procedure

NEF068A

NCEC0330

NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 4 minutes at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-293. With GST Follow the procedure “With CONSULT-II” above.

EC-291

DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0331

: Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models CRANKSHAFT POSITION SENSOR (OBD)

TCM (TRANSMISSION CONTROL MODULE)

ECM

YEC839

EC-292

DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0332

RETIGHTEN GROUND SCREWS

1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws.

©

2

GO TO 2.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect crankshaft position sensor (OBD) and ECM harness connectors.

Crankshaft position sensor (OBD) harness connector Cooling fan motor (Left side)

SEF226X

2. Check continuity between ECM terminal 65 and crankshaft position sensor (OBD) harness connector terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the harness for open or short between crankshaft position sensor (OBD) and ECM.

©

4

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK GROUND CIRCUIT

1. Reconnect ECM harness connectors. 2. Check harness continuity between crankshaft position sensor harness connector terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between crankshaft position sensor (OBD) and ECM I Harness for open or short between crankshaft position sensor (OBD) and TCM (Transmission control module)

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-293

DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)

SR20DE

Component Inspection

6

CHECK IMPROPER INSTALLATION

Loosen and retighten the fixing bolt of the crankshaft position sensor (OBD). Then retest.

Trouble is not fixed.

7

©

GO TO 7.

CHECK CRANKSHAFT POSITION SENSOR (OBD)

Refer to “Component Inspection”, EC-SR-294. OK or NG OK

©

GO TO 8.

NG

©

Replace crankshaft position sensor (OBD).

8

CHECK GEAR TOOTH

Visually check for chipping flywheel or drive plate gear tooth (cog). OK or NG OK

©

GO TO 9.

NG

©

Replace the flywheel or drive plate.

9

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

Component Inspection CRANKSHAFT POSITION SENSOR (OBD) 1. 2. 3. 4.

NCEC0333S01

Disconnect crankshaft position sensor (OBD) harness connector. Loosen the fixing bolt of the sensor. Remove the sensor. Visually check the sensor for chipping.

SEF960N

5.

NCEC0333

Check resistance as shown in the figure. Resistance: M/T models 166 - 204 Ω [at 20°C (68°F)] CVT models Approx. 285 Ω [at 20°C (68°F)]

SEF231W

EC-294

SR20DE

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

System Description

System Description

NCEC0560

The malfunction information related to CVT is transferred through the line (circuit) from TCM (Transmission Control Module) to ECM. Therefore, be sure to erase the malfunction information such as DTC not only in TCM (Transmission Control Module) but also ECM after the CVT related repair.

ECM Terminals and Reference Value

NCEC0561

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 91

WIRE COLOR PU/Y

ITEM

CONDITION

CVT check signal

DATA (DC Voltage)

[Ignition switch “ON”] [Engine is running]

0 - Approximately 5V

On Board Diagnosis Logic DTC No. P1605 1605

Malfunction is detected when ... I An incorrect signal from TCM (Transmission Control Module) is sent to ECM.

Check Items (Possible Cause) I Harness or connectors [The communication line circuit between ECM and TCM (Transmission Control Module) is open or shorted.] I Dead (Weak) battery I TCM (Transmission Control Module)

DTC Confirmation Procedure

NEF068A

NCEC0562

NCEC0563

NOTE: If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and let it idle for at least 40 seconds. 4) If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-297. With GST Follow the procedure “With CONSULT-II” above.

EC-295

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

SR20DE

Wiring Diagram

Wiring Diagram

TCM (TRANSMISSION CONTROL MODULE)

.

NCEC0564

: Detectable line for DTC : Non-detectable line for DTC

ATCK

ECM F101

YEC850

EC-296

DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE

SR20DE Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4.

CHECK INPUT SIGNAL CIRCUIT Turn ignition switch “OFF”. Disconnect ECM harness connector and TCM harness connector. Refer to A/T section for TCM location. Check harness continuity between ECM terminal 91 and TCM terminal 15. Refer to wiring diagram. Also check harness for short to ground and short to power. OK or NG

OK

©

GO TO 2.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

2

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-297

NCEC0565

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH

SR20DE

Component Description

Component Description

NCEC0424

When the gear position is “P” (CVT models only) or “N”, park/ neutral position (PNP) switch is “ON”. ECM detects the park/neutral position when continuity with ground exists.

SEF740W

CONSULT-II Reference Value in Data Monitor Mode

NCEC0425

Specification data are reference values. MONITOR ITEM

CONDITION I Ignition switch: ON

P/N POSI SW

SPECIFICATION

Shift lever: “P” or “N”

ON

Except above

OFF

ECM Terminals and Reference Value

NCEC0426

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

42

WIRE COLOR

G/OR

ITEM

PNP switch

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] I Gear position is “Neutral position” (M/T models) I Gear position is “N” or “P” (CVT models)

Approximately 0V

[Ignition switch “ON”] I Except the above gear position

BATTERY VOLTAGE (11 - 14V)

On Board Diagnosis Logic DTC No. P1706 1706

Malfunction is detected when ... I The signal of the PNP switch is not changed in the process of engine starting and driving.

NCEC0427

Check Items (Possible Cause) I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch

DTC Confirmation Procedure

NCEC0428

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 9 seconds before conducting the next test.

EC-298

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH

SR20DE

DTC Confirmation Procedure (Cont’d)

1) 2) 3) 4)

NEF118A

With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 50 consecutive seconds.

ENG SPEED

1,500 - 3,400 rpm

COOLAN TEMP/S

More than 70°C (158°F)

B/FUEL SCHDL

2.4 - 12.0 msec

VHCL SPEED SE

64 - 130 km/h (40 - 81 MPH)

Selector lever

Suitable position

5)

If 1st trip DTC is detected, go to “Diagnostic Procedure”, ECSR-301.

Overall Function Check

NCEC0429

Use this procedure to check the overall function of the park/neutral position switch circuit. During this check, a 1st trip DTC might not be confirmed. Without CONSULT-II 1) Turn ignition switch “ON”. 2) Check voltage between ECM terminal 42 (PNP switch signal) and body ground under the following conditions. Condition (Gear position)

SEF137X

“P” (CVT only) and “N” position Except the above position

3)

Voltage (V) (Known good data) Approx. 0 BATTERY VOLTAGE (11 - 14V)

If NG, go to “Diagnostic Procedure”, EC-SR-301.

EC-299

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0430

ECM : Detectable line for DTC : Non-detectable line for DTC : Hyper CVT models : M/T models

NEUTRAL

NEUTRAL POSITION SWITCH

P

Ds R

OTHERS

N

D

PARK/NEUTRAL POSITION SWITCH

YEC851

EC-300

DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0431

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect PNP switch harness connector.

SEF740W

3. Check harness continuity between PNP switch harness connector terminal 2 and body ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 3.

NG

©

GO TO 2.

2

DETECT MALFUNCTIONING PART

Check the harness for open or short between PNP switch and body ground. ©

3

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 42 and PNP switch harness connector terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

GO TO 4.

4

DETECT MALFUNCTIONING PART

Check the harness for open or short between ECM and PNP switch. ©

5

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK PNP SWITCH

Refer to MT section or AT section. OK or NG OK

©

GO TO 6.

NG

©

Replace PNP switch.

6

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

EC-301

SR20DE

INJECTOR Component Description

Component Description

NCEC0435

The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the injector circuit, the coil in the injector is energized. The energized coil pulls the needle valve back and allows fuel to flow through the injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. SEF138X

CONSULT-II Reference Value in Data Monitor Mode

NCEC0436

MONITOR ITEM

INJ PULSE -B1

B/FUEL SCHDL

CONDITION

SPECIFICATION

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.2 msec

2,000 rpm

1.9 - 2.8 msec

I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

Idle

2.4 - 3.2 msec

2,000 rpm

1.4 - 2.8 msec

ECM Terminals and Reference Value

NCEC0437

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Idle speed

101 103 105 107

R/B Y/B G/B L/B

Injector Injector Injector Injector

No. No. No. No.

1 2 3 4

SEF011W

BATTERY VOLTAGE (11 - 14V)

[Engine is running] I Warm-up condition I Engine speed is 2,000 rpm

SEF012W

EC-302

SR20DE

INJECTOR

Wiring Diagram

Wiring Diagram

NCEC0434

IGNITION SWITCH ON or START FUSE BLOCK (J/B)

Refer to EL-POWER.

Detectable line for DTC Non-detectable line for DTC Hyper CVT models M/T models

INJECTOR No.1

INJECTOR No.2

INJECTOR No.3

INJECTOR No.4

ECM

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

YEC251

EC-303

INJECTOR

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0438

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.

NEF105A

3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound.

MEC703B

Clicking noise should be heard. OK or NG OK

©

INSPECTION END

NG

©

GO TO 2.

2 1. 2. 3. 4.

CHECK POWER SUPPLY Stop engine. Disconnect injector harness connector. Turn ignition switch “ON”. Check voltage between terminal 2 and ground with CONSULT-II or tester.

SEF986W

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-304

SR20DE

INJECTOR

Component Inspection

3

DETECT MALFUNCTIONING PART

Check the following. I 10A fuse I Harness connectors F13, F60 I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between injector and fuse ©

4

Repair harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between injector harness connector terminal 1 and ECM terminals 101, 103, 105, 107. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F13, F60 I Harness for open or short between ECM and injector ©

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK INJECTOR

Refer to “Component Inspection”, EC-SR-305. OK or NG OK

©

GO TO 7.

NG

©

Replace injector.

7

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

Component Inspection INJECTOR 1. 2.

NCEC0439 NCEC0439S01

Disconnect injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 13.5 - 17.5Ω [at 25°C (77°F)] If NG, replace injector.

SEF139X

EC-305

SR20DE

IGNITION SIGNAL Component Description

Component Description

Ignition coil harness connector

Camshaft position sensor and power transistor harness connector

NCEC0566

IGNITION COIL & POWER TRANSISTOR (BUILT INTO DISTRIBUTOR) NCEC0566S01

Distributor SEF211X

The ignition coil is built into distributor. The ignition signal from the ECM is sent to the power transistor. The power transistor switches on and off the ignition coil primary circuit. As the primary circuit is turned on and off, the proper high voltage is induced in the coil secondary circuit. The distributor is not repairable and must be replaced as an assembly except distributor cap and rotor head.

CONSULT-II Reference Value in Data Monitor Mode

NCEC0567

MONITOR ITEM

IGN TIMING

CONDITION I I I I

Engine: After warming up Air conditioner switch: OFF Shift lever: “N” No-load

SPECIFICATION

Idle

15° BTDC

2,000 rpm

Approx. 40° BTDC

ECM Terminals and Reference Value

NCEC0568

Specification data are reference values and are measured between each terminal and 43 (ECM ground). TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) Approximately 0.3V

[Engine is running] I Warm-up condition I Idle speed

SEF996V

35

W/L

Ignition signal Approximately 0.8V

[Engine is running] I Engine speed is 2,000 rpm

SEF997V

EC-306

SR20DE

IGNITION SIGNAL

ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage) Approximately 13V

[Engine is running] I Warm-up condition I Idle speed

SEF998V

36*1

G

Ignition check

Approximately 12V

[Engine is running] I Engine speed is 2,000 rpm

SEF999V

*1: If so equipped

EC-307

SR20DE

IGNITION SIGNAL Wiring Diagram

Wiring Diagram

NCEC0571

BATTERY

Refer to EL-POWER.

ECM RELAY

CONDENSER RESISTOR

IGNITION COIL

POWER TRANSISTOR

DISTRIBUTOR

SPARK PLUG

YEC852

EC-308

IGNITION SIGNAL

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

NCEC0572

CHECK ENGINE START

Turn ignition switch “OFF”, and restart engine. Is engine running? Yes or No Yes

©

GO TO 7.

No

©

GO TO 2.

2

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect ignition coil harness connector. Ignition coil harness connector

Camshaft position sensor and power transistor harness connector

Distributor SEF211X

3. Turn ignition switch “ON”. 4. Check voltage between terminal 8 and ground with CONSULT-II or tester.

SEF257W

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

3

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors E90, F73 I Harness for open or short between ignition coil and ignition switch ©

4

Repair harness or connectors.

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect power transistor harness connector. 3. Check harness continuity between terminal 5 and engine ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-309

IGNITION SIGNAL

SR20DE

Component Inspection

5

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 35 and power transistor terminal 6. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

6

CHECK IGNITION COIL, POWER TRANSISTOR

Refer to “Component Inspection”, EC-SR-310. OK or NG OK

©

GO TO 7.

NG

©

Replace malfunctioning component(s).

7

CHECK INPUT SIGNAL CIRCUIT (If so equipped)

1. 2. 3. 4.

Stop engine. Disconnect ignition coil harness connector. Disconnect ECM harness connector. Check harness continuity between ignition coil terminal 7 and ECM terminal 36. Refer to wiring diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

Component Inspection

NCEC0573

IGNITION COIL

Coil tower metal tip

Disconnect distributor harness connector. Check continuity between terminal 7 and 8 on distributor. Continuity should exist. If NG, replace distributor.

3. 4.

For checking secondary coil, remove distributor cap. Check resistance between ignition coil harness connector terminal 7 and coil tower metal tip 9 (secondary terminal) on the distributor head.

SEF237X

Terminal 7 - 8 (Primary coil) 8 - secondary terminal on distributor head (Secondary coil) Coil tower metal tip

NCEC0573S01

1. 2.

SEF238X

If NG, replace distributor.

EC-310

Resistance [at 25°C (77°F)] Approximately 0.5 - 1.0Ω Approximately 25 kΩ

SR20DE

IGNITION SIGNAL

Component Inspection (Cont’d)

POWER TRANSISTOR 1. 2.

Distributor

NCEC0573S02

Disconnect power transistor harness connector. Check power transistor resistance between terminals 5 and 7. Terminals

Resistance

Result

Except 0Ω

OK

0Ω

NG

5 and 7

If NG, replace distributor. SEF239X

EC-311

SR20DE

START SIGNAL CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0441

Specification data are reference values. MONITOR ITEM START SIGNAL

CONDITION

SPECIFICATION

I Ignition switch: ON , START , ON

OFF , ON , OFF

ECM Terminals and Reference Value

NCEC0442

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 41

WIRE COLOR

B/Y

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”]

Approximately 0V

[Ignition switch “START”]

9 - 12V

Start signal

EC-312

SR20DE

START SIGNAL

Wiring Diagram

Wiring Diagram

NCEC0440

BATTERY

Refer to EL-POWER.

Detectable line for DTC Non-detectable line for DTC Hyper CVT models OFF

ST

IGNITION SWITCH

M/T models

ACC ON

FUSE BLOCK (J/B)

ECM

.

REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) E104 FUSE BLOCK Junction Box (J/B)

YEC252

EC-313

SR20DE

START SIGNAL Diagnostic Procedure

Diagnostic Procedure 1

=NCEC0443

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

©

GO TO 2.

No

©

GO TO 3.

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Turn ignition switch “ON”. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

PEF111P Condition

“START SIGNAL”

IGN “ON”

OFF

IGN “START”

ON MTBL0140

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Turn ignition switch to “START”. 2. Check voltage between ECM terminal 41 and ground under the following conditions. CONNECT

SEF142X Condition

Voltage

Ignition switch “START” Except above

Battery voltage Approximately 0V

MTBL0143

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

EC-314

START SIGNAL

SR20DE Diagnostic Procedure (Cont’d)

4

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 (CVT: M81, F115) I 10A fuse I Harness for open or short between ECM and ignition switch OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114.

©

INSPECTION END

EC-315

SR20DE

FUEL PUMP System Description

System Description Sensor

Input Signal to ECM

Camshaft position sensor (REF)

Engine speed

Ignition switch

Start signal

NCEC0444

ECM function ECM

Actuator

Fuel pump relay

The ECM activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the ECM receives a 180° signal from the camshaft position sensor, it knows that the engine is rotating, and causes the pump to perform. If the 180° signal is not received when the ignition switch is on, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition

Fuel pump operation

Ignition switch is turned to ON.

Operates for 2 seconds

Engine running and cranking

Operates

When engine is stopped

Stops in 1.5 seconds

Except as shown above

Stops

Component Description

NCEC0501

A turbine type design fuel pump is used in the fuel tank.

AEC801

CONSULT-II Reference Value in Data Monitor Mode

NCEC0445

MONITOR ITEM

FUEL PUMP RLY

CONDITION

SPECIFICATION

I Ignition switch is turned to ON (Operates for 2 seconds) I Engine running and cranking I When engine is stopped (stops in 1.5 seconds)

ON

I Except as shown above

OFF

ECM Terminals and Reference Value

NCEC0446

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

21

WIRE COLOR

B/P

ITEM

CONDITION

DATA (DC Voltage)

[Ignition switch “ON”] I For 2 seconds after turning ignition switch “ON” [Engine is running]

0 - 1V

[Ignition switch “ON”] I More than 1 second after turning ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

Fuel pump relay

EC-316

SR20DE

FUEL PUMP

Wiring Diagram

Wiring Diagram

NCEC0447

IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

Refer to EL-POWER.

Detectable line for DTC Non-detectable line for DTC Hyper CVT models

FUEL PUMP RELAY

M/T models

FUEL PUMP

ECM

.

REFER TO THE FOLLOWING M1 FUSE BLOCK Junction Box (J/B) B8 FUSE BLOCK Junction Box (J/B)

YEC253

EC-317

FUEL PUMP

SR20DE

Diagnostic Procedure

Diagnostic Procedure 1

NCEC0448

CHECK OVERALL FUNCTION

1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with fingers.

Fuel filter

Pinch

SEF241X

Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned “ON”. OK or NG OK

©

INSPECTION END

NG

©

GO TO 2.

2

CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay located on the fuse block.

SEF071X

3. Turn ignition switch “ON”. 4. Check voltage between terminals 1, 3 and ground with CONSULT-II or tester.

SEF144X

Voltage: Battery voltage OK or NG OK

©

GO TO 4.

NG

©

GO TO 3.

EC-318

FUEL PUMP

SR20DE Diagnostic Procedure (Cont’d)

3

DETECT MALFUNCTIONING PART

Check the following. I 15A fuse I Harness for open or short between fuse and fuel pump relay ©

4

Repair harness or connectors.

CHECK POWER GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector.

SEF299W

3. Check harness continuity between fuel pump harness connector terminal 2 and body ground, terminal 1 and fuel pump relay connector terminal 9J. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 6.

NG

©

GO TO 5.

5

DETECT MALFUNCTIONING PART

Check the following. I Harness for open or short between fuel pump and body ground I Harness for open or short between fuel pump and fuel pump relay ©

6

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK OUTPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 21 and fuel pump relay connector terminal 19C. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 8.

NG

©

GO TO 7.

7

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors M50, F104 (CVT: M81, F115) I Harness for open or short between ECM and fuel pump relay

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

EC-319

FUEL PUMP

SR20DE

Component Inspection

8

CHECK FUEL PUMP RELAY

Refer to “Component Inspection”, EC-SR-320. OK or NG OK

©

GO TO 9.

NG

©

Replace fuel pump relay.

9

CHECK FUEL PUMP

Refer to “Component Inspection”, EC-SR-320. OK or NG OK

©

GO TO 10.

NG

©

Replace fuel pump.

10

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

Component Inspection

NCEC0449

FUEL PUMP RELAY

NCEC0449S01

Check continuity between terminals 3 and 5. Conditions

Continuity

12V direct current supply between terminals 1 and 2

Yes

No current supply

No

If NG, replace relay. SEF145X

FUEL PUMP 1. 2.

Disconnect fuel pump harness connector. Check resistance between terminals 1 and 2. Resistance: 0.2 - 5.0Ω [at 25°C (77°F)] If NG, replace fuel pump.

SEF326W

EC-320

NCEC0449S02

SR20DE

POWER STEERING OIL PRESSURE SWITCH

Component Description

Component Description

Power steering oil pressure switch

NCEC0451

The power steering oil pressure switch is attached to the power steering high-pressure tube and detects a power steering load. When a power steering load is detected, it signals the ECM. The ECM adjusts the IACV-AAC valve to increase the idle speed and adjust for the increased load.

NEF124A

CONSULT-II Reference Value in Data Monitor Mode

NCEC0452

Specification data are reference values. MONITOR ITEM

PW/ST SIGNAL

CONDITION I Engine: After warming up, idle the engine

SPECIFICATION

Steering wheel in neutral position (forward direction)

OFF

The steering wheel is fully turned

ON

ECM Terminals and Reference Value

NCEC0453

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO.

46

WIRE COLOR

PU/W

ITEM

CONDITION

[Engine is running] Power steering oil pressure I Steering wheel is fully turned switch [Engine is running] I Steering wheel is not turned

EC-321

DATA (DC Voltage)

Approximately 0V Approximately 5V

POWER STEERING OIL PRESSURE SWITCH

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0450

YEC254

EC-322

POWER STEERING OIL PRESSURE SWITCH

SR20DE Diagnostic Procedure

Diagnostic Procedure 1

=NCEC0454

INSPECTION START

Do you have CONSULT-II? Yes or No Yes

©

GO TO 2.

No

©

GO TO 3. CONNECT

2

CHECK OVERALL FUNCTION

With CONSULT-II 1. Start engine. 2. Check “PW/ST SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

PEF591I Steering is in neutral position

OFF

Steering is turned

ON MTBL0141

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

3

CHECK OVERALL FUNCTION

Without CONSULT-II 1. Start engine. 2. Check voltage between ECM terminal 46 and ground under the following conditions.

SEF148X Condition

Voltage

When steering wheel is turned quickly

Approximately 0V

Except above

Approximately 5V MTBL0142

OK or NG OK

©

INSPECTION END

NG

©

GO TO 4.

EC-323

SR20DE

POWER STEERING OIL PRESSURE SWITCH Component Inspection

4

CHECK GROUND CIRCUIT

1. Turn ignition switch “OFF”. 2. Disconnect power steering oil pressure switch harness connector. 3. Check harness continuity between power steering oil pressure switch harness terminal 2 and engine ground. Refer to wiring diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 5.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

5

CHECK INPUT SIGNAL CIRCUIT

1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 46 and power steering oil pressure switch harness terminal 1. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK

©

GO TO 7.

NG

©

GO TO 6.

6

DETECT MALFUNCTIONING PART

Check the following. I Harness connectors F4, E42 I Harness for open or short between ECM and power steering oil pressure switch ©

7

Repair open circuit or short to ground or short to power in harness or connectors.

CHECK POWER STEERING OIL PRESSURE SWITCH

Refer to “Component Inspection”, EC-SR-324. OK or NG OK

©

GO TO 8.

NG

©

Replace power steering oil pressure switch.

8

CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-SR-114. ©

INSPECTION END

Component Inspection

NCEC0455

POWER STEERING OIL PRESSURE SWITCH 1. 2.

NCEC0455S01

Disconnect power steering oil pressure switch harness connector then start engine. Check continuity between terminals 1 and 2. Refer to wiring diagram. Conditions

Continuity

Steering wheel is being turned

Yes

Steering wheel is not being turned

No

If NG, replace power steering oil pressure switch.

EC-324

SR20DE

ELECTRICAL LOAD SIGNAL

CONSULT-II Reference Value in Data Monitor Mode

CONSULT-II Reference Value in Data Monitor Mode

NCEC0548

Specification data are reference values. MONITOR ITEM

LOAD SIGNAL

HEATER FAN SW

CONDITION

I Engine: running

I Ignition switch: ON

SPECIFICATION

Rear window defogger or headlamp “ON”

ON

Except the above

OFF

Heater fan switch: ON

ON

Heater fan switch: OFF

OFF

ECM Terminals and Reference Value

NCEC0549

Specification data are reference values and are measured between each terminal and 48 (ECM ground). TERMINAL NO. 50

51

WIRE COLOR

R

LG/B

ITEM

Electric load signal

Blower fan SW

CONDITION

DATA (DC Voltage)

[Engine is running] I Headlamp switch or rear window defogger switch is “ON”

BATTERY VOLTAGE (11 - 14V)

[Ignition switch “ON”] I Blower fan switch is “ON”

Approximately 0V

[Ignition switch “ON”] I Blower fan switch is “OFF”

Approximately 5V

EC-325

ELECTRICAL LOAD SIGNAL

SR20DE

Wiring Diagram

Wiring Diagram

NCEC0550

YEC255

EC-326

SR20DE

ELECTRICAL LOAD SIGNAL

Wiring Diagram (Cont’d)

DIODE TYPE - 1

To EL-DEF

: Detectable line for DTC

FUSE BLOCK (J/B)

: Non-detectable line for DTC Refer to EL-POWER.

TIME CONTROL UNIT

: With XENON headlamp or daytime light system : Except

HD

: Hyper CVT models : M/T models

To EL-H/LAMP

OFF

2ND

1ST PASS

COMBINATION SWITCH (LIGHTING SWITCH)

With XENON headlamp . . . R/W Except XENON headlamp . . . G With daytime light system . . . 1 Without daytime light system . . . 2 With daytime light system . . . 2 Without daytime light system . . . 1

With daytime light system and with XENON headlamp. . . R/l

LOW HIGH

With daytime light system and without XENON headlamp. . . P/B Without daytime light system . . . OR/L

Headlamp relay LH

DIODE

To EL-LAMP

ECM

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YEC853

EC-327

ELECTRICAL LOAD SIGNAL

SR20DE

Wiring Diagram (Cont’d)

DIODE TYPE - 2

YEC095A

EC-328

MI & DATA LINK CONNECTORS

SR20DE Wiring Diagram

Wiring Diagram

NCEC0466

YEC096A

EC-329

SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure Regulator

Fuel Pressure Regulator Fuel pressure at idling kPa (bar, kg/cm2, psi)

NCEC0467

Vacuum hose is connected

Approximately 235 (2.35, 2.4, 34)

Vacuum hose is disconnected

Approximately 294 (2.94, 3.0, 43)

Idle Speed and Ignition Timing

NCEC0468

Target idle speed*1

rpm

No-load*3 (in “P” or “N” position)

Air conditioner: ON

rpm

In “P” or “N” position

825 or more

In “P” or “N” position

15°±2° BTDC

Ignition timing*2 Throttle position sensor idle position

*1: *2: *3: I I I

750±50

V

0.35 - 0.65

Throttle position sensor harness connector connected Throttle position sensor harness connector disconnected Under the following conditions: Air conditioner switch: OFF Electrical load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position

Ignition Coil Primary voltage

V

NCEC0574

Battery voltage (11 - 14)

Primary resistance [at 25°C (77°F)]

kΩ

Secondary resistance [at 25°C (77°F)]

2.2 kΩ

Approximately 17

Mass Air Flow Sensor

NCEC0470

Supply voltage (Heater)

V

Battery voltage (11 - 14)

Supply voltage (Sensor)

V

Approximately 5

Output voltage

V

1.3 - 1.7*

Mass air flow (Using CONSULT-II or GST)

2.5 - 5.0 at idle* 7.1 - 12.5 at 2,500 rpm*

g⋅m/sec

*: Engine is warmed up to normal operating temperature and idling under no-load.

Engine Coolant Temperature Sensor Temperature

°C (°F)

Resistance

kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

Fuel Pump Resistance [at 25°C (77°F)] Ω

NCEC0471

NCEC0473

0.2 - 5.0

IACV-AAC Valve Resistance [at 20°C (68°F)] Ω Between terminals 1 - 2, 2 - 3, 4 - 5 and 5 - 6

NCEC0474

20 - 24

Injector Resistance [at 25°C (77°F)] Ω

NCEC0475

13.5 - 17.5

EC-330

SERVICE DATA AND SPECIFICATIONS (SDS) Throttle Position Sensor

Throttle Position Sensor Throttle valve conditions

NCEC0477

Resistance [at 25°C (77°F)]

Completely closed

Approximately 0.6 kΩ

Partially open

0.6 - 4.0 kΩ

Completely open

Approximately 4.0 kΩ

Heated Oxygen Sensor 1 (Front) Heater Resistance [at 25°C (77°F)] Ω

NCEC0478

2.3 - 4.3

Intake Air Temperature Sensor Temperature

°C (°F)

Resistance

NCEC0480

kΩ

20 (68)

2.2 - 2.6

80 (176)

0.31 - 0.37

EVAP Canister Purge Volume Control Valve Resistance [at 20°C (68°F)] Ω

NCEC0481

31 - 35

Heated Oxygen Sensor 1 (Rear) Heater Resistance [at 25°C (77°F)] Ω

NCEC0483

2.3 - 4.3

Crankshaft Position Sensor (OBD) Resistance [at 25°C (77°F)] Ω

166 - 204

EC-331

NCEC0575

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

EC-332

ENGINE CONTROL SYSTEM SECTION

EC EC

CONTENTS CD20T PRECAUTIONS AND PREPARATION.......................... 3 Special Service Tools ................................................ 3 Engine Fuel & Emission Control System .................. 5 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 6 Precautions for On Board Diagnostic (OBD) System of Engine ...................................................... 6 Precautions ................................................................ 7 ENGINE AND EMISSION CONTROL OVERALL SYSTEM......................................................................... 9 Engine Control Module Component Parts Location ..................................................................... 9 Circuit Diagram .........................................................11 System Diagram ...................................................... 12 Vacuum Hose Drawing ............................................ 13 System Chart ........................................................... 14 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ............................................. 15 Glow Control System............................................... 15 Fuel Injection System .............................................. 15 Fuel Injection Timing System .................................. 18 Air Conditioning Cut Control.................................... 20 Cooling Fan Control................................................. 20 CRANKCASE VENTILATION SYSTEM...................... 21 Description ............................................................... 21 Blow-by Control Valve ............................................. 21 Ventilation Hose....................................................... 21 INJECTION NOZZLE................................................... 22 Removal and Installation ......................................... 22 Test and Adjustment ................................................ 22 ELECTRONIC FUEL INJECTION PUMP.................... 24 Removal................................................................... 24 Installation................................................................ 25

Disassembly and Assembly..................................... 26 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ............................................................. 27 CONSULT-II ............................................................. 27 TROUBLE DIAGNOSIS - INTRODUCTION................ 33 Introduction .............................................................. 33 Diagnostic Worksheet.............................................. 34 TROUBLE DIAGNOSIS - WORK FLOW .................... 35 Work Flow................................................................ 35 Description for Work Flow ....................................... 36 TROUBLE DIAGNOSIS - BASIC INSPECTION......... 37 Basic Inspection....................................................... 37 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 39 Diagnostic Trouble Chart ......................................... 39 Symptom Matrix Chart............................................. 47 CONSULT-II Reference Value in Data Monitor Mode ........................................................................ 50 Major Sensor Reference Graph in Data Monitor Mode ........................................................................ 51 ECM Terminals and Reference Value ..................... 52 TROUBLE DIAGNOSIS FOR POWER SUPPLY........ 59 Main Power Supply and Ground Circuit.................. 59 TROUBLE DIAGNOSIS 1............................................ 62 Mass Air Flow Sensor (MAFS) ................................ 62 TROUBLE DIAGNOSIS 2............................................ 66 Engine Coolant Temperature (ECT) Sensor ........... 66 TROUBLE DIAGNOSIS 3............................................ 70 Vehicle Speed Sensor (VSS) .................................. 70 TROUBLE DIAGNOSIS 4............................................ 74 Control Sleeve Position Sensor (CSPS) ................. 74 TROUBLE DIAGNOSIS 5............................................ 78 Electric Governor ..................................................... 78 TROUBLE DIAGNOSIS 6............................................ 82

Injection Timing Control Valve ................................. 82 TROUBLE DIAGNOSIS 7............................................ 86 Engine Control Module (ECM) ................................ 86 TROUBLE DIAGNOSIS 8............................................ 87 Cooling Fan (Overheat) ........................................... 87 TROUBLE DIAGNOSIS 9............................................ 97 Needle Lift Sensor (NLS) ........................................ 97 TROUBLE DIAGNOSIS 10........................................ 100 Fuel Cut Solenoid Valve ........................................ 100 TROUBLE DIAGNOSIS 11........................................ 104 Fuel Temperature Sensor (FTS)............................ 104 TROUBLE DIAGNOSIS 12........................................ 108 Accelerator Position Sensor & Switch................... 108 TROUBLE DIAGNOSIS 13.........................................114 Crankshaft Position Sensor (TDC) .........................114 TROUBLE DIAGNOSES 14 .......................................118 Glow Control System..............................................118

TROUBLE DIAGNOSES 15 ...................................... 126 Air Conditioner Cut Control ................................... 126 TROUBLE DIAGNOSES 16 ...................................... 129 EGRC-Solenoid Valve ........................................... 129 TROUBLE DIAGNOSES 17 ...................................... 136 Brake Switch.......................................................... 136 TROUBLE DIAGNOSES 18 ...................................... 140 ECM Relay............................................................. 140 TROUBLE DIAGNOSES 19 ...................................... 141 MI & Data Link Connectors ................................... 141 TROUBLE DIAGNOSES 20 ...................................... 145 Start Signal ............................................................ 145 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 147 General Specifications........................................... 147 Injection Nozzle ..................................................... 147 Inspection and Adjustment .................................... 147

When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”. For clarification of system component abbreviations and terminology read GI section “SAE J1930 TERMINOLOGY LIST”.

EC-2

PRECAUTIONS AND PREPARATION Special Service Tools Tool number Tool name

Description

KV11289004 Nozzle cleaning kit 1 KV11290012 p Box 2 KV11290110 p Brush 3 KV11290122 p Nozzle oil sump scraper 4 KV11290140 p Nozzle needle tip cleaner 5 KV11290150 p Nozzle seat scraper 6 KV11290210 p Nozzle holder 7 KV11290220 p Nozzle hole cleaning needle NT296

KV109E0010 Break-out box

NT825

KV109E0050 Y-cable adapter

NT826

KV11292010 Nozzle centering device

NT293

KV11100300 No. 2-4 injection nozzle holder socket

NT563

EC-3

CD20T

PRECAUTIONS AND PREPARATION Special Service Tools (Cont’d) Tool number Tool name

Description

KV119E0030 No. 1 injection nozzle holder socket

NT648

EC-4

CD20T

PRECAUTIONS AND PREPARATION

CD20T

Engine Fuel & Emission Control System

ECM (ECCS-D control module) ● Do not disassemble ECM. ● If a battery terminal is disconnected, the memory will return to the ECM value. The ECM will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation. ● When ECM is removed for inspection, make sure to ground the ECM mainframe.

WIRELESS EQUIPMENT ● When installing C.B. ham radio or a mobile

1) 2)

3)

BATTERY ● Always use a 12 volt battery as power

4)

source.

phone, be sure to observe the following as it may adversely affect electronic control systems depending on its installation location. Keep the antenna as far as possible away from the ECM. Keep the antenna feeder line more than 20 cm (7.9 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standing-wave ratio can be kept small. Be sure to ground the radio to vehicle body.

● Do not attempt to disconnect battery cables

while engine is running.

ELECTRONIC FUEL INJECTOR PUMP

ECM mainframe

● Do not disconnect pump harness connectors

with engine running. ● Do not disassemble or adjust electronic fuel

injection pump, except for the following parts. Camshaft position sensor (pump) Injection timing control valve Fuel cut solenoid valve

ECM PARTS HANDLING ● Handle mass air flow sensor carefully to avoid damage. ● Do not disassemble mass air flow sensor. ● Do not clean mass air flow sensor with any type of detergent. ● Do not disassemble No. 1 injection nozzle (builtin needle lift sensor). ● Even a slight leak in the air intake system can cause serious problems. ● Do not shock or jar the camshaft position sensor (TDC).

WHEN STARTING ● Do not depress accelerator pedal when starting. ● Immediately after starting, do not rev up engine unnecessarily. ● Do not rev up engine just prior to shutdown.

ECM HARNESS HANDLING ● Connect ECM harness connectors securely.

A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. ● Keep ECM harness at least 10 cm (3.9 in) away from adjacent harnesses, to prevent an ECM system malfunction due to receiving external noise, degraded operation of ICs, etc. ● Keep ECM parts and harnesses dry. ● Before removing parts, turn off ignition switch and then disconnect battery ground cable.

NEF390

EC-5

PRECAUTIONS AND PREPARATION

CD20T

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NCEC0002

The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).

Precautions for On Board Diagnostic (OBD) System of Engine NCEC0003

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) ● Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL section, “Description”, “HARNESS CONNECTOR”. ● Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. ● Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the EGR system or fuel injection system, etc. ● Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer.

EC-6

PRECAUTIONS AND PREPARATION

CD20T

Precautions ●

Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off.

●

When connecting ECM harness connectors, push in both sides of the connector until you hear a click. Maneuver the lever until you hear the three connectors on the inside click. Refer to the figure at left.

●

Before replacing ECM, perform Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-CD-52.

●

If MI illuminates or blinks irregularly during engine running, water may have accumulated in fuel filter. Drain water from fuel filter. If this does not correct the problem, perform specified trouble diagnostic procedures. After performing each TROUBLE DIAGNOSIS, perform “OVERALL FUNCTION CHECK” or “DTC (Diagnostic Trouble Code) CONFIRMATION PROCEDURE”. The DTC should not be displayed in the “DTC CONFIRMATION PROCEDURE” if the repair is completed. The “OVERALL FUNCTION CHECK” should be a good result if the repair is completed.

SEF289H

SEF881Y

MEF040D

●

SAT652J

EC-7

PRECAUTIONS AND PREPARATION Precautions (Cont’d) ●

CD20T

When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor.

SEF348N

EC-8

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

CD20T

Engine Control Module Component Parts Location

YEC133A

EC-9

CD20T ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Location (Cont’d)

YEC134A

EC-10

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

CD20T

Circuit Diagram

YEC099A

EC-11

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

CD20T

System Diagram

YEC125A

EC-12

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

CD20T

Vacuum Hose Drawing

YEC131A 1 p 2 p 3 p

EGRC-solenoid valves A and B to EGR valve EGRC-solenoid valves A and B to air duct EGRC-solenoid valve A to vacuum pump

Refer to “System Diagram” on previous page for vacuum control system.

EC-13

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

CD20T

System Chart Crankshaft position sensor (TDC)

E

Control sleeve position sensor

E

Fuel temperature sensor

E

Mass air flow sensor

E

Engine coolant temperature sensor

E

Needle lift sensor

E

Accelerator position sensor

E

ECM Accelerator position switch

E

Air conditioner switch

E

Ignition switch (ON & ST POS.)

E

Battery voltage

E

Vehicle speed sensor or ABS actuator and electric unit (control unit)

E

Brake switch

E

Atmospheric pressure sensor

E

Fuel injection control

E

Electric governor

E

Fuel injection timing control

E

Injection timing control valve

E

Fuel cut control

E

Fuel cut solenoid valve

E

Glow control system

E

Glow relay & glow lamp

E

On board diagnostic system

E

Malfunction indicator (On the instrument panel)

E

EGR valve control

E

EGRC-solenoid valve A & B

E

Cooling fan control

E

Cooling fan relays

E

Air conditioning cut control

E

Air conditioner relay

E

Cooling fan motor control

E

Cooling fan relay

E

EC-14

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

CD20T

Glow Control System SYSTEM DESCRIPTION Crankshaft position sensor (TDC)

Engine speed E

E

Glow relay

E

Glow lamp

E

Glow plugs

ECM Engine coolant temperature sensor

Engine coolant temperature E

When coolant temperature is lower than 75°C (167°F): ● Ignition switch ON After the ignition switch has been turned to ON, the glow relay turns ON for a period of time depending on the engine coolant temperature, allowing current to flow through the glow plugs. ● Starting After starting the engine, current will flow through the glow plugs for 300 seconds, or until the coolant temperature exceeds 50°C (122°F).

Fuel Injection System SYSTEM DESCRIPTION Three types of fuel injection control are provided to accommodate the engine operating conditions; normal control, idle control and start control. The ECM determines the appropriate fuel injection control. Under each control, the amount of fuel injected is compensated to improve engine performance. The ECM performs duty cycle control on the electric governor (built into the fuel injection pump) according to sensor signals to compensate the amount of fuel injected to the preset value.

START CONTROL Input/output signal line Engine coolant temperature sensor Crankshaft position sensor (TDC)

Fuel injection volume

Control sleeve position sensor

Engine coolant temperature Engine speed Control sleeve position

E

E

ECM

E

Electric governor

E

When starting, the ECM adapts the fuel injection system for the start control. The amount of fuel injected at engine starting is a preset program value in the ECM. The program is determined by the engine speed and engine coolant temperature. For better startability under cool engine conditions, the lower the coolant temperature becomes, the greater the amount of fuel injected. The ECM ends the start control when the engine speed reaches a coolant temperature dependent value.

Coolant temperature getting lower

Engine rpm SEF648S

EC-15

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System (Cont’d)

CD20T

IDLE CONTROL Input/output signal line Engine coolant temperature

Engine coolant temperature sensor

Engine speed

Crankshaft position sensor (TDC)

Air conditioner operation

Air conditioner switch

Control sleeve position

Control sleeve position sensor

Idle position

Accelerator position switch Vehicle speed sensor or ABS actuator and electric unit (control unit)

E

E

E

ECM E

E

Electric governor

E

Vehicle speed

E

When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine to keep engine speed constant. During the first 270s after a cold start, the ECM also provides the system with a fast idle control in response to the engine coolant temperature.

NORMAL CONTROL Input/output signal line Engine speed

Crankshaft position sensor (TDC)

Control sleeve position

Control sleeve position sensor

Accelerator position

Accelerator position sensor

Fuel injection volume

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Accelerator opening larger

Engine rpm

E

E

ECM E

E

Electric governor

E

The amount of fuel injected under normal driving conditions is determined according to sensor signals. The crankshaft position sensor (TDC) detects engine speed and the accelerator position sensor detects accelerator position. These sensors send signals to the ECM. The fuel injection data, predetermined by correlation between various engine speeds and accelerator positions, are stored in the ECM memory, forming a map. The ECM determines the optimal amount of fuel to be injected using the sensor signals in comparison with the map.

SEF649S

EC-16

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System (Cont’d)

CD20T

FUEL TEMPERATURE COMPENSATION Input/output signal line Fuel temperature sensor Crankshaft position sensor (TDC) Control sleeve position sensor

Fuel temperature Engine speed Control sleeve position

E

E

ECM

E

Electric governor

E

The amount of fuel leaking at or around high-pressure parts inside the fuel injection pump varies with fuel temperature and engine speed. This will result in a difference between the target amount of fuel injected and the actual amount. The ECM compensates for the actual amount depending on the signal from the fuel temperature sensor, the control sleeve position sensor and the crankshaft position sensor.

DECELERATION CONTROL Input/output signal line Accelerator sensor Camshaft position sensor (PUMP)

Accelerator position Engine speed

E

ECM

E

Electric governor

E

The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator sensor and camshaft position sensor (PUMP).

EC-17

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

CD20T

Fuel Injection Timing System SYSTEM DESCRIPTION The fuel injection timing system determines the optimal fuel injection timing, based on engine speed, injection quantity, engine coolant temperature and atmospheric pressure. The timing is formed by a basic value (Basic Control) and two correction values. By performing a duty cycle signal on the timing control valve, the ECM allows the valve to provide optimal injection timing. The ECM also performs feedback control on the timing control valve using the signal from the needle lift sensor which detects the actual fuel injection timing.

BASIC CONTROL Input/output signal line Crankshaft position sensor (TDC)

Injection timing

Needle lift sensor Control sleeve position sensor

Fuel injection timing

BTDC (degree)

Engine speed

Control sleeve position

E

E

ECM

E

Injection timing control valve

E

The optimal fuel injection timing data, predetermined in proportion to engine speeds and amount of fuel injected, are stored in the ECM memory. The ECM uses the data to control the fuel injection timing.

Fuel injection volume Large

Small

Engine rpm SEF650S

HIGH ALTITUDE COMPENSATION Crankshaft position sensor Control sleeve position sensor Atmospheric pressure sensor

Engine speed Control sleeve position Atmospheric pressure Injection timing

Needle lift sensor Fuel temperature sensor

Fuel temperature

E

E

E

ECM

E

Injection timing control valve

E

E

Fuel injection timing compensation

For better drivability in high altitude areas, the fuel injection timing is advanced and the fuel quantity is reduced according to the atmospheric pressure. Normal

High altitude Engine rpm NEF771

EC-18

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection Timing System (Cont’d)

CD20T

ENGINE COOLANT TEMPERATURE COMPENSATION (During driving) Input/output signal line Crankshaft position sensor (TDC) Engine coolant temperature sensor

Engine speed Engine coolant temperature

E

E

ECM Injection timing

Needle lift sensor

Fuel injection timing compensation

Control sleeve position sensor

Control sleeve position

E

E

Injection timing control valve

E

For better exhaust efficiency under cool engine conditions, the fuel injection timing is controlled within a compensation range depending on the engine speed, engine coolant temperature and amount of fuel injected.

Engine coolant temperature Low

High Engine rpm SEF652S

ENGINE COOLANT TEMPERATURE COMPENSATION (When starting) Input/output signal line Crankshaft position sensor (TDC) Engine coolant temperature sensor

Engine coolant temperature Ignition timing

Needle lift sensor

Fuel injection timing compensation

Engine speed

E

E

ECM

E

Injection timing control valve

E

For better startability under cool engine conditions, the fuel injection timing is compensated according to the engine coolant temperature.

Engine coolant temperature

High

Low Engine rpm SEF651S

EC-19

ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

CD20T

Air Conditioning Cut Control INPUT/OUTPUT SIGNAL LINE Air conditioner switch or ABS actuator and electric unit (control unit)

Air conditioner “ON” signal

E

Accelerator valve opening angle

Accelerator position sensor

E

Vehicle speed

Vehicle speed sensor

E

Air conditioner relay

E

Engine coolant temperature

Engine coolant temperature sensor

ECM

E

SYSTEM DESCRIPTION This system improves acceleration when the air conditioner is used. When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds. When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues until the coolant temperature returns to normal.

Cooling Fan Control INPUT/OUTPUT SIGNAL LINE Vehicle speed sensor or ABS actuator and electric unit (control unit)

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner “ON” signal

E

E

ECM

Cooling fan relay(s)

E

E

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air conditioner ON signal. The control system has 3-step control [OFF/LOW/HIGH].

Operation Air conditioner is ON Engine coolant temperature °C (°F)

Engine coolant temperature °C (°F)

Air conditioner is OFF

.

102 (216) .

96 (205) .

.

102 (216) .

96 (205)

.

20 80 (12) (50) Vehicle speed km/h (mph) Cooling fans do not operate

.

20 (12)

.

80 (50)

Vehicle speed km/h (mph)

Cooling fans operate at low speed

EC-20

Cooling fans operate at high speed

NEF772

CRANKCASE VENTILATION SYSTEM Blow-by control valve

CD20T

Description ●

In this system blow-by gas is sucked into the air inlet pipe through the control valve after oil separation by the oil separator in the rocker cover.

Baffle plate

FRESH AIR BLOW BY GAS SEF851S

Blow-by Control Valve ●

Blow-by control valve

Check control valve for clogging and abnormalities.

Intake manifold

Rocker cover SEC586B

Ventilation Hose 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.

SEC692

EC-21

INJECTION NOZZLE

CD20T

CAUTION: ● Do not disassemble injection nozzle assembly. Entrust disassembly or adjustment to BOSCH service shop. ● Plug flare nut with a cap or rag so that no dust enters the nozzle.

Nozzle side

Combustion chamber side

NEF396 No. 1 injection nozzle

Removal and Installation 1. Remove fuel injection tube and spill tube. 2. Remove injection nozzle assembly. Also remove gasket from nozzle end. 3. Install injection nozzle in the reverse order of removal. Injection nozzle to engine: : 59 - 69 N·m (6.0 - 7.0 kg-m, 43 - 51 ft-lb) Injection nozzle to tube: : 22 - 25 N·m (2.2 - 2.5 kg-m, 16 - 18 ft-lb) Spill tube: : 39 - 49 N·m (4.0 - 5.0 kg-m, 29 - 36 ft-lb) a. Always clean the nozzle holes. b. Always use new injection nozzle gasket. c. Note that small washer should be installed in specified direction. d. Bleed air from fuel system.

NEF774

Test and Adjustment WARNING: When using nozzle tester, be careful not to allow diesel fuel sprayed from nozzle to contact your hands or body, and make sure your eyes are properly protected with goggles.

INJECTION PRESSURE TEST 1. Install nozzle to injection nozzle tester and bleed air from flare nut.

EF791A

EC-22

INJECTION NOZZLE Test and Adjustment (Cont’d)

SEF672A

CD20T

2. Pump the tester handle slowly (one time per second) and watch the pressure gauge. 3. Read the pressure gauge when the injection pressure just starts dropping. Initial injection pressure: Used 14,423 - 15,651 kPa (144.2 - 156.5 bar, 148 - 159 kg/cm2, 2,091 - 2,269 psi) New 15,000 - 16,000 kPa (150.0 - 160.0 bar, 153 - 163 kg/cm2, 2,175 - 2,320 psi) Always check initial injection pressure using a new nozzle. If the pressure is not correct, replace nozzle assembly.

LEAKAGE TEST 1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6 bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection pressure. 2. Check that there is no dripping from the nozzle tip or around the body. 3. If there is leakage, replace nozzle. Good

Faulty SEF674A

SPRAY PATTERN TEST 1. Check spray pattern by pumping tester handle one full stroke per second. a. If main spray angle is within 30 degrees as shown, injection nozzle is good. b. It is still normal even if a thin stream of spray deviates from the main spray (pattern B). 2. Test again and if spray pattern is not corrected, replace nozzle. SEF079S

EC-23

CD20T

ELECTRONIC FUEL INJECTION PUMP

6.3 - 8.2 (0.64 - 0.84, 55.6 - 72.9) 16 - 21 (1.6 - 2.1, 12 - 15)

13 - 18 (1.3 - 1.8, 9 - 13) Front of engine 16 - 21 (1.6 - 2.1, 12 - 15)

31 - 37 (3.2 - 3.8, 23 - 27) 59 - 69 (6.0 - 7.0, 43 - 51)

49 - 59 (5.0 - 6.0, 36 - 43)

24 - 27 (2.4 - 2.8, 17 - 20)

: N·m (kg-m, in-lb)

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8) 24 - 27 (2.4 - 2.8, 17 - 20)

: N·m (kg-m, ft-lb) 1 p 2 p 3 p

Rear back cover Injection pump sprocket Injection pump bracket

4 p 5 p 6 p

Water connector Bracket Bracket

7 p 8 p

NEF777

Electronic fuel injection pump Key

Removal 1. Remove battery. Disconnect electronic injection pump harness connectors.

2. Set No. 1 piston at TDC on its compression stroke. TDC: Crankshaft pulley notch without painted mark 3. Remove fuel hoses (supply, return and spill) and injection tubes. 4. Remove air duct and injection pump timing belt cover. 5. Remove injection pump timing belt. Refer to EM section (“Injection Pump Timing Belt”).

Injection timing mark (Yellow painted mark)

TDC (Without painted mark)

SEF655S

6. Remove injection pump sprocket with Tool. ● Remove key from injection pump shaft and store safely.

SEF656S

EC-24

ELECTRONIC FUEL INJECTION PUMP Removal (Cont’d)

CD20T

7. Remove injection pump assembly.

SEF657S Injection pump sprocket Key

Alignment mark

Installation 1. Install key on injection pump shaft, then install injection pump sprocket. 2. Install injection pump timing belt. Refer to EM section (“Injection Pump Timing Belt”). 3. Adjust injection timing. Refer to “Basic Inspection”, EC-CD-37. 4. Install all parts removed.

NEF866

Fuel cut solenoid valve 20 - 25 (2.0 - 2.5, 14 - 18)

O-ring

Washer 20 - 25 (2.0 - 2.5, 14 - 18)

: Do not reuse : N·m (kg-m, in-lb)

7 - 10 (0.7 - 1.0, 61 - 87)

: N·m (kg-m, ft-lb) NEF778

EC-25

ELECTRONIC FUEL INJECTION PUMP

CD20T

Disassembly and Assembly CAUTION: ● Do not disassemble the parts not shown in the illustration above. ● Before installing injection timing control valve, apply a coat of diesel fuel to O-ring and its mating area. Insert injection timing control valve straight into bore in fuel pump body. After properly positioning injection timing control valve, visually check for fuel leaks. ● After assembling the parts, erase Diagnostic Trouble Code (DTC), and perform DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).

EC-26

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CD20T

CONSULT-II Fuse box

CONSULT-II INSPECTION PROCEDURE 1. Turn off ignition switch. 2. Connect “CONSULT-II” to data link connector for CONSULTII. (Data link connector for CONSULT-II is located behind the fuse box cover.)

Data link connector for CONSULT-II

NEF225A

3. 4. 5. 6.

Turn on ignition switch. Touch “START”. Touch “ENGINE”. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual.

PEF895K

PEF216U

EC-27

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

CD20T

ENGINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS

ENGINE CONTROL MODULE COMPONENT PARTS

Item

INPUT

OUTPUT

DATA MONITOR

Camshaft position sensor (PUMP) *1

X *2

X

Mass air flow sensor

X

X

Engine coolant temperature sensor

X

X

Control sleeve position sensor

X

X

Fuel temperature sensor

X

X

Vehicle speed sensor or ABS actuator and electric unit (control unit)

X

X

Accelerator position sensor

X

X

Accelerator position switch

ACTIVE TEST

X

X

Brake lamp switch

X *2

X

Crankshaft position sensor (TDC)

X

X

Needle lift sensor

X

X

Ignition switch (start signal)

X

Ignition switch (ON signal)

X

Air conditioner switch

X

Brake switch

X

Battery voltage

X

Injection timing control valve

X

X

X

Fuel cut solenoid valve

X

X

X

Air conditioner relay

X

Glow relay

X

X

EGRC-solenoid valve

X

X

Cooling fan relay

X

X

X: Applicable *1: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse. *2: CONSULT-II may not display, but self-diagnostic results are available with MI.

EC-28

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

CD20T

SELF-DIAGNOSTIC MODE Regarding items detected in “SELF-DIAG RESULTS” mode, refer to “Diagnostic Trouble chart”.

DATA MONITOR MODE Monitored item [Unit]

ECM Main input signals signals

Description

CKPS⋅RPM (TDC) [rpm]

q q

●

The engine speed computed from the crankshaft position sensor (TDC) signal is displayed.

CMPS⋅RPM PUMP [rpm]

q q

●

The engine speed computed from the camshaft position sensor (PUMP) signal is displayed.

●

The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed.

●

The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit (control unit) signal is displayed.

●

The fuel temperature (determined by the signal voltage of the fuel temperature sensor) is displayed.

●

The accelerator position sensor signal voltage is displayed.

●

Indicates [ON/OFF] condition from the accelerator position switch signal.

●

The control sleeve position sensor signal voltage is displayed.

●

The power supply voltage of ECM is displayed.

●

Indicates [ON/OFF] condition from the starter signal.

●

Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal.

●

Indicates [ON/OFF] condition of the stio lamp switch.

●

Indicates [ON/OFF] condition of the stio lamp switch 2.

●

Indicates [ON/OFF] condition from ignition switch.

●

The signal voltage of the mass air flow sensor is displayed.

●

The actual injection timing angle determined by the ECM (an approximate average angle between injection start and end from TDC) is displayed.

●

The target fuel injection quantity (determined by the ECM according to the input signal) is indicated.

COOLAN TEMP/S [°C] or [°F]

VHCL SPEED SE [km/h] or [mph]

q q q q

FUEL TEMP SEN [°C] or [°F]

q q

ACCEL POS SEN [V]

q q q q q

OFF ACCEL POS [ON/OFF] C/SLEEV POS/S [V] BATTERY VOLT [V] START SIGNAL [ON/OFF]

q q q q q

AIR COND SIG [ON/OFF]

q q

BRAKE SW [ON/OFF]

q q q q q q

BRAKE SW2 [ON/OFF] IGN SW [ON/OFF] MAS AIR/FL SE [V] ACT INJ TIMG [°]

TARGET F/INJ [mm3/STROKE]

q q

Remarks

●

When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed.

●

After starting the engine, [OFF] is displayed regardless of the starter signal.

●

When the engine is stopped, a certain value is indicated.

NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-29

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitored item [Unit]

ECM Main input signals signals

FUEL CUT S/V [ON/OFF]

Description ●

●

AIR COND RLY [ON/OFF] GLOW RLY [ON/OFF] COOLING FAN [LOW/HI/OFF]

EGRC SOL/V A [ON/OFF]

The control condition of the fuel cut solenoid valve (determined by ECM according to the input signal) is indicated. OFF ... Fuel cut solenoid valve is not operating. ON ... Fuel cut solenoid valve is operating.

q

●

The air conditioner relay control condition (determined by ECM according to the input signal) is indicated.

q

●

The glow relay control condition (determined by ECM according to the input signal) is displayed.

●

Indicates the control condition of the cooling fans (determined by ECM according to the input signal). LOW ... Operates at low speed. HI ... Operates at high speed. OFF ... Stopped.

q

●

●

●

The control condition of the EGRCsolenoid valve (determined by ECM according to the input signal) is indicated. OFF ... EGRC-solenoid valve is not operating. ON ... EGRC-solenoid valve is operating.

EC-30

CD20T

Remarks ●

When the fuel cut solenoid valve is not operating, fuel supply is shut off.

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

CD20T

ACTIVE TEST MODE TEST ITEM

CONDITION

TARGET F/INJ

COOLING FAN

FUEL CUT SOL/V

EGRC SOL/V A

GLOW RLY

CHECK ITEM (REMEDY)

If trouble symptom disappears, see CHECK ITEM.

●

Control sleeve position sensor

● ●

Ignition switch: ON Operate the cooling fan at “LOW”, “HI” speed and turn “OFF” using CONSULT-II.

Cooling fan moves at “LOW”, “HI” speed and stops.

● ●

Harness and connector Cooling fan motor

● ●

Ignition switch: ON Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating sound.

● ●

Harness and connector Solenoid valve

● ●

Ignition switch: ON Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound.

Solenoid valve makes an operating sound.

● ●

Harness and connector Solenoid valve

●

Ignition switch: ON (Engine stopped) Glow relay makes the operating Turn the glow relay “ON” and sound. “OFF” using CONSULT-II and listen to operating sound.

● ●

Harness and connector Fuel pump relay

Engine: Return to the original trouble condition Retard the injection timing using CONSULT-II.

●

Adjust initial injection timing

●

●

●

INJ TIMING

JUDGEMENT

Engine: Return to the original trouble condition Fix the target injection quantity using CONSULT-II.

●

●

If trouble symptom disappears, see CHECK ITEM.

EC-31

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

CD20T

REAL TIME DIAGNOSIS IN DATA MONITOR MODE CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1. “AUTO TRIG” (Automatic trigger): ● The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC and malfunction item will be displayed at the moment the malfunction is detected by ECM. DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA MONITOR cannot continue any longer after the malfunction detection. 2. “MANU TRIG” (Manual trigger): ● Malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. Use these triggers as follows: 1. “AUTO TRIG” ● While trying to detect the malfunction item by performing the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. ● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. The moment a malfunction is found the malfunction item will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.) 2. “MANU TRIG” ● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition.

“SETTING”

“AUTO TRIG” A malfunction can be displayed on “DATA MONITOR” screen automatically if detected.

“MANU TRIG” A malfunction can not be displayed on “DATA MONITOR” screen automatically even if detected. PEF529Q

EC-32

TROUBLE DIAGNOSIS — Introduction

CD20T

Introduction

SEF858S

SEF233G

The engine has an ECM to control major systems such as fuel injection control, fuel injection timing control, glow control system, etc. The ECM accepts input signals from sensors and instantly drive the electronic fuel injection pump use the data to based on current ambient conditions. It is essential that both input and output signals are correct and stable. At the same time, it is important that there are no problems such as vacuum leaks, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than catastrophically. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only may not be sufficient to determine the cause of the problems. A road test with CONSULT-II or a circuit tester connected should be performed. Follow the “Work Flow” on the next page. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on a vehicle with an electronically controlled engine.

SEF234G

EC-33

CD20T

TROUBLE DIAGNOSIS — Introduction Diagnostic Worksheet KEY POINTS WHAT ..... WHEN ..... WHERE ..... HOW .....

Vehicle & engine model Date, Frequencies Road conditions Operating conditions, Weather conditions, Symptoms

There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one shown below in order to organize all the information for troubleshooting.

SEF907L

WORKSHEET SAMPLE Customer name

Model & Year

VIN

Engine #

Trans.

Mileage

Incident Date

Manuf. Date

In Service Date

Symptoms

MR/MS

l Startability

l Impossible to start l No combustion l Partial combustion l Partial combustion when warming-up engine l Partial combustion when cooling down engine l Possible but hard to start l Others [ ]

l Idling

l No fast idle l Others [

l Driveability

l Stumble l Others [

l Engine stall

l At the time of start l While accelerating l Just after stopping

l Unstable l Surge

Incident occurrence

l Just after delivery l In the morning

Frequency

l All the time

Weather conditions

l Not affected

Weather

l Fine [

Temperature

l Hot

Engine conditions

l Knock

l Low idle

l Lack of power ]

l While idling l While decelerating l While loading l Recently l At night l In the daytime

l Under certain conditions

l Raining

l Snowing ]

l Warm

l Cold

l High idle ]

l Cool

l Sometimes

l Others

l Cold

l During warm-up

l Humid

°F

l After warm-up

Engine speed 0

2,000

l In suburbs

4,000

Road conditions

l In town

l Highway

Driving conditions

l Not affected l At starting l While idling l At racing l While accelerating l While cruising l While decelerating l While turning (RH/LH)

6,000

8,000 rpm

l Off road (up/down)

Vehicle speed 0 Malfunction indicator

l Turned on

10

20

30

l Not turned on

EC-34

40

50

60

70

80

90

100 mph

TROUBLE DIAGNOSIS — Work Flow

CD20T

Work Flow CHECK IN H

Listen to customer complaints. (Get symptoms.)

..........................................

STEP I

.....................................

STEP II

H

Check, print out or write down, and erase Diagnostic Trouble (malfunction item). Symptoms collected.

No symptoms, except MI lights up, or Malfunction Code exists at STEP II. H

Verify the symptom by driving in the condition the customer described. Normal Code (at STEP II)

....................................................................................*1 STEP III

Malfunction Code (at STEP II) H

H

Verify the malfunction item by performing the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. H E

..................................... *2

Choose the appropriate action. Malfunction Code (at STEP II or IV)

H

.....................................*1 STEP IV

STEP V

Normal Code (at both STEP II and IV)

BASIC INSPECTION SYMPTOM BASIS (at STEP I or III) ...........................................................E H

Perform inspections according to Symptom Matrix Chart. H

H

STEP VI

TROUBLE DIAGNOSIS FOR SPECIFIC MALFUNCTION ITEM. H

REPAIR/REPLACE H

NG FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then, erase the unnecessary (already fixed) Malfunction Item in ECM.

.....................................

STEP VII

OK H

CHECK OUT *1: If the incident cannot be duplicated, refer to GI section (“Incident Simulation Tests”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”). *2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT”, EC-CD-59.

EC-35

TROUBLE DIAGNOSIS — Work Flow

CD20T

Description for Work Flow STEP

DESCRIPTION

STEP I

Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORKSHEET” as shown on the previous page.

STEP II

Before confirming the concern, check and write down (print out using CONSULT-II) the malfunction item, then erase the code. The malfunction item can be used when duplicating the incident at STEP III & IV. Study the relationship between the cause, specified by malfunction item, and the symptom described by the customer. (The “Symptom Matrix Chart” will be useful. Refer to EC-CD-47.)

STEP III

Try to confirm the symptom and under what conditions the incident occurs. The “DIAGNOSTIC WORK SHEET” is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section. If the malfunction code is detected, skip STEP IV and perform STEP V.

STEP IV

Try to detect the malfunction item by driving in (or performing) the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Check and read the malfunction item by using CONSULT-II. During the malfunction item verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section. In case the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK” instead. The malfunction item cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the DTC detection.

STEP V

Take the appropriate action based on the results of STEP I through IV. If the malfunction code is indicated, proceed to specific TROUBLE DIAGNOSIS for the malfunction item. If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-CD-37. Then perform inspections according to the Symptom Matrix Chart. Refer to EC-CD-47.

STEP VI

Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”. Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO TRIG)” mode. Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II. Refer to EC-CD-52. The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI section (“Circuit Inspection”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”). Repair or replace the malfunctioning parts.

STEP VII

Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and circumstances which resulted in the customer’s initial complaint. Perform the “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” and confirm the normal code is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the previous one. Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) malfunction item in ECM.

EC-36

TROUBLE DIAGNOSIS — Basic Inspection

CD20T

Basic Inspection Precaution: Perform Basic Inspection without electrical or mechanical loads applied; ● Headlamp switch is off, ● Air Conditioner switch is off, ● Rear defogger switch is off, ● Steering wheel is in the straight-ahead position, etc. SEF142I

Priming pump

SEF671S

.

Diesel tacho tester

BEFORE STARTING 1. Check service records for any recent repairs that may indicate a related problem, or the current need for scheduled maintenance. 2. Open engine hood and check the following: ● Harness connectors for faulty connections ● Vacuum hoses for splits, kinks, or faulty connections ● Wiring for faulty connections, pinches, or cuts 3. Using priming pump, bleed air from fuel system. Refer to “Fuel Filter Check” in MA section. H

.

Injection tube

CONNECT CONSULT-II TO THE VEHICLE. Connect “CONSULT-II” to the data link connector for CONSULT-II and select “ENGINE” from the menu. Refer to ECCD-27.

SEF689S

H

DOES ENGINE START? Yes

H

Run engine for 10 minutes. H PEF190P

CHECK IDLE SPEED. Read engine idle speed in “DATA MONITOR” mode with CONSULT-II. 825 rpm ± 25 (in N position) ----------------------------------------------------------------- OR ----------------------------------------------------------------Check idle speed using tachometer tester. 825 rpm ± 25 (in N position)

(Go to

A p

H

on next page.)

EC-37

No

E

Turn ignition switch to the “LOCK” position, wait 5 seconds and then start engine. If engine fails to start, check malfunction item.

CD20T

TROUBLE DIAGNOSIS — Basic Inspection Basic Inspection (Cont’d) A p

H

SEF661S

Plunger lift timing mark (Yellow painted mark)

TDC (Without painted mark)

SEF655S

Increase Decrease

CHECK INJECTION TIMING. 1. Set No. 1 piston at TDC on its compression stroke. TDC: Without painted mark 2. Remove injection tubes and air bleeder on the back of injection pump. 3. Set dial gauge so its indicator points to somewhere between 1.0 and 2.0 mm (0.039 and 0.079 in) on the scale. 4. Turn crankshaft 2 turns clockwise and check that dial gauge indicates the same value again. 5. Turn crankshaft counterclockwise about 100 degrees, then turn crankshaft slowly clockwise, and set dial gauge indicator to 0 mm at the position it stops. 6. Turn crankshaft clockwise and set it at plunger lift timing mark using the mark on the crankshaft pulley. plunger lift timing mark: Yellow painted mark 7. Read plunger lift. Plunger lift: 0.89 ± 0.08 mm (0.0350 ± 0.0031 in) at plunger lift timing mark ● When repeating the checking, start with step 5.

OK

E

Bleed air from fuel system. After this inspection, unnecessary diagnostic trouble code No. might be displayed. Erase the stored memory in ECM. Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”. OK H

INSPECTION END

NG H

SEF662S

SEF657S

Adjusting 1. If plunger lift is not within the specified value, adjust by turning injection pump. ● If indication is smaller than the specified value, turn pump body away from engine. ● If indication is larger than the specified value, turn pump body towards engine. 2. Tighten injection pump securing bolts and nuts. Nut: : 20 - 25 N·m (2.0 - 2.6 kg-m, 15 - 18 ft-lb) Bolt: : 25 - 35 N·m (2.6 - 3.6 kg-m, 18 - 26 ft-lb) 3. Remove dial gauge and install air bleeder with new washer. 4. Install injection tubes. Flare nut: : 14 - 20 N·m (1.4 - 2.0 kg-m, 10 - 15 ft-lb) 5. Bleed air from fuel system. Refer to “Water Draining, Fuel Filter Check and Replacement” of “ENGINE MAINTENANCE” in MA section.

EC-38

E

Go to

TROUBLE DIAGNOSIS — General Description

CD20T

Diagnostic Trouble Chart ENGINE RELATED ITEMS Detected items Malfunction is detected when ... (Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Mass air flow sensor circuit (MASS AIR FLOW SEN)

●

An excessively high or low voltage from the sensor is detected by the ECM.

Engine coolant temperature sensor circuit (COOLANT TEMP SEN)

●

An excessively high or low voltage from the sensor is detected by the ECM.

Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit (VEHICLE SPEED SEN)

●

The almost 0 km/h (0 mph) signal from the sensor is detected by the ECM even when vehicle is being driven.

Control sleeve position sensor circuit (CONT SLEEV POS SEN)

●

An excessively high or low voltage from the sensor is detected by the ECM. An incorrect voltage signal from the sensor is detected by the ECM during engine running.

Fuel injection feedback 2 (F/INJ F/B 2)

●

The fuel injection feedback system (consists of the ECM, electric governor and control sleeve position sensor) does not operate properly.

Fuel injection timing feedback (F/INJ TIMG F/B)

●

The fuel injection timing feedback system (consists of the ECM, fuel injection timing control valve and needle lift sensor) does not operate properly.

●

Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).

EC-39

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

—: Not applicable *2

*1 Overall Function Check

Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor

IGN: ON

—

—

EC-CD-62

Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor

IGN: ON

—

Lighting up

EC-CD-66

—

LIFTING

—

EC-CD-70

Harness or connectors (The sensor circuit is open or shorted.) Control sleeve position sensor

RUNNING

—

Lighting up

EC-CD-74

Main power supply circuit (ECM terminals 23 , 45 ), 68 and fuse Harness or connectors (Electric governor and control sleeve position sensor circuit) Electronic fuel injection pump ECM Electric governor

RUNNING (DRIVING)

—

Lighting up

EC-CD-78

Harness or connectors (Injection timing control valve, Needle lift sensor and Crankshaft position sensor (TDC) circuit] Injection timing control valve Needle lift sensor Crankshaft position sensor Air in fuel line

RUNNING (DRIVING)

—

Lighting up

EC-CD-82

Check Items (Possible Cause)

●

● ●

● ●

●

●

● ●

●

● ● ● ●

● ● ● ●

MI Reference Illumination Page

Confirmation Procedure Quick Ref.

Harness or connectors (The sensor circuit is open or shorted.) Vehicle speed sensor or ABS actuator and electric unit (control unit)

*1:

●

*2:

●

● ●

This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each TROUBLE DIAGNOSIS. The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each TROUBLE DIAGNOSIS.

EC-40

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

ENGINE RELATED ITEMS Detected items Malfunction is detected when ...

(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Cooling fan (OVER HEAT)

●

An excessive high engine coolant temperature sensor signal is detected by the ECM. (Overheat)

ECM2 (ECM2)

●

ECM calculation function is malfunctioning.

Needle lift sensor circuit (NEEDLE LIFT SEN)

●

An incorrect signal from the sensor is detected by the ECM during engine running.

Fuel cut solenoid valve 1 (FUEL CUT S/V 1)

●

Fuel cut solenoid valve circuit is malfunctioning.

Fuel temperature sensor circuit (FUEL TEMP SENSOR)

●

An excessively high or low voltage from the sensor is detected by the ECM.

Accelerator position sensor circuit (ACCEL POS SENSOR)

●

An excessively high or low voltage from the sensor is detected by the ECM.

Crankshaft position sensor (TDC) [CRANK POS SEN (TDC)]

●

An incorrect signal from the sensor is detected by the ECM during engine running and cranking.

No failure (NO SELF DIAGNOSTIC FAILURE INDICATED)

No malfunction is detected by the ECM.

Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).

EC-41

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

—: Not applicable *2

*1 Check Items (Possible Cause)

Confirmation Procedure Quick Ref.

Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● Radiator hose ● Radiator ● Radiator cap ● Water pump ● Thermostat ● Fan belt ● Engine coolant temperature sensor For more information, refer to “12 MAIN CAUSES OF OVERHEATING”. (EC-CD-95)

Overall Function Check

MI Reference Illumination Page

●

—

IGN: ON (RUNNING)

Lighting up

EC-CD-78

IGN: ON

—

Lighting up

EC-CD-86

●

ECM

●

Harness or connectors (The sensor circuit is open or shorted.) Needle lift sensor Air in fuel line Clogging No. 1 injection nozzle

RUNNING

—

Lighting up

EC-CD-97

Harness or connectors (The solenoid valve circuit is open or shorted.) Fuel cut solenoid valve

RUNNING

—

Lighting up

EC-CD-100

Harness or connectors (The sensor circuit is open or shorted.) Fuel temperature sensor

IGN: ON

—

—

EC-CD-104

Harness or connectors (The sensor circuit is open or shorted.) Accelerator position sensor Accelerator position switch

IGN: ON

—

Lighting up

EC-CD-108

RUNNING

—

Lighting up

EC-CD-114

●

Harness or connectors (The sensor circuit is open or shorted.) Crankshaft position sensor (TDC)

●

No failure —

—

—

—

● ● ● ●

● ●

● ●

● ● ●

*1:

●

*2:

●

● ●

This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS.

EC-42

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

ENGINE RELATED ITEMS Detected items Malfunction is detected when ...

(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) Atmospheric pressure sensor *5 (—) *3

●

An excessively high or low voltage from the sensor is detected by the ECM.

Glow relay circuit (GLOW RELAY)

●

Glow relay circuit is open or shorted.

ECM (—)*3

●

ECM reference voltage (2.5V) is excessively high or low.

Air conditioner relay circuit (—)*3

●

Air conditioner relay circuit is shorted.

EGRC-solenoid valve A (EGR SYS)

●

EGRC-solenoid valve A is open or shorted.

Brake switch circuits (—)*3

●

Brake switch circuits are open or shorted.

ECM (—)*3

●

ECM version number or switching function is not plausible.

ECCS-D relay circuit (—)*3

●

ECCS-D relay shut-off time is too late.

Ignition switch “ON” signal circuit (—)*3

●

Ignition switch “ON” signal evaluation circuit in ECM is malfunctioning.

Injection timing control valve circuit (INJ TIMING CONT/V)

●

Injection timing control valve circuit is open or shorted.

Camshaft position sensor (PUMP)*4 (—)*3

●

An improper signal is calculated by the ECM.

Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).

EC-43

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

—: Not applicable *1 Confirmation Procedure Quick Ref.

Check Items (Possible Cause)

●

*2 Overall Func- MI Reference tion Check Illumination Page

ECM IGN: ON

—

—

EC-CD-86

IGN: ON

—

—

EC-CD-118

IGN: ON

—

—

EC-CD-86

IGN: ON

—

—

EC-CD-126

Harness or connectors (The EGRC-solenoid valve A circuit is open or shorted.) EGRC-solenoid valve

RUNNING

—

Lighting up

EC-CD-129

RUNNING

—

Lighting up

EC-CD-136

●

Harness or connectors (Brake switch circuits are open or shorted.) Brake lamp switch RDNT brake switch

●

ECM

IGN: ON

—

—

EC-CD-86

●

IGN: ON

—

Lighting up

EC-CD-86

●

Harness or connectors (The ECCS-D relay circuit is shorted.) ECCS-D relay ECM

●

ECM IGN: ON

—

Lighting up

EC-CD-86

IGN: ON

—

Lighting up

EC-CD-82

RUNNING

—

Lighting up

EC-CD-97

●

Harness or connectors (The glow relay circuit is open or shorted.) Glow relay

●

ECM

●

Harness or connectors (The air conditioner relay circuit is open or shorted.) Air conditioner relay

●

● ●

● ●

●

●

●

● ● ● ●

*1: *2:

*3: *4: *5:

Harness or connectors (The injection timing control valve circuit is open or shorted.) Injection timing control valve ECM Needle lift sensor Low battery voltage

This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. ● The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. ● During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. ● This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS. CONSULT-II may not detect, but self-diagnostic results are available with MI. Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse. The atmospheric pressure sensor is located inside the ECM and is not replaceable. ●

EC-44

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

ENGINE RELATED ITEMS Detected items Malfunction is detected when ...

(Screen terms for CONSULT-II, “SELF-DIAG RESULTS” mode) MI (—)*3

●

MI (malfunction indicator) circuit is open or shorted.

GLOW LAMP CIRCUIT (—)*3

●

Glow lamp circuit is open or shorted.

Abbreviations for Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE” IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit. RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit. LIFTING : Lifting up the vehicle, running engine and spinning wheels are required. DRIVING : Driving the vehicle in the specified pattern is required. Abbreviations for Quick Reference of “OVERALL FUNCTION CHECK” IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists). RUNNING : Running engine is required for the ECM to detect a malfunction (if one exists). LIFTING : Lifting up the vehicle, running engine and spinning wheels are required for the ECM to detect a malfunction (if one exists). DRIVING : Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction (if one exists).

EC-45

TROUBLE DIAGNOSIS — General Description Diagnostic Trouble Chart (Cont’d)

CD20T

—: Not applicable *1 Check Items (Possible Cause)

●

● ● ●

●

*1:

Confirmation Procedure Quick Ref.

*2 Overall Func- MI Reference tion Check Illumination Page

Harness or connectors (The MI circuit is open or shorted.) MI lamp ECM

IGN: ON

—

—

EC-CD-141

Harness or connectors (The glow indicator lamp circuit is open or shorted.) Glow lamp

IGN: ON

—

—

EC-CD-118

This is Quick Reference of “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. Details are described in each specific TROUBLE DIAGNOSIS. *2: ● The “OVERALL FUNCTION CHECK” is a simplified and effective way to inspect a component or circuit. In some cases, the “OVERALL FUNCTION CHECK” is used rather than a “DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE”. When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the “NG” result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection. ● During an “NG” OVERALL FUNCTION CHECK, the malfunction item might not be confirmed. ● This is Quick Reference of “OVERALL FUNCTION CHECK”. Details are described in each specific TROUBLE DIAGNOSIS. *3: CONSULT-II may not detect, but self-diagnostic results are available with MI. ●

EC-46

CD20T

TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart

●

●

q

q q

●

●

q

●

Electric injection pump mainframe

●

●

●

q q q q q

●

Injection nozzle

q q q q q q q

●

Glow system

q q

●

●

●

Engine body

q q

●

●

●

q q q

q q

q q

q q

q

q

●

●

●

●

●

●

q

●

q q q

●

●

●

Air cleaner and ducts

●

●

●

EC-47

Feature of symptom, Check point

Reference page EC-CD-38

●

q

EC-CD-38

q

q q q

—

*1

EC-CD-22

*2

●

EGR system

● ; High Possibility Item q; Low Possibility Item *1: Insufficient or excess amount. Governor malfunction may be the cause. *2: Depends on open-valve pressure and spray pattern. *3: Caused mainly by insufficient compression pressure. *4: Symptom varies depending on off-position of air duct, etc.

HA

q

●

q

DEAD BATTERY (UNDER CHARGE)

ABNORMAL SMOKE COLOR AP

q q q q q

WHITE SMOKE

BLACK SMOKE

EXCESSIVE OIL CONSUMPTION

EXCESSIVE FUEL CONSUMPTION

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

SLOW/NO RETURN TO IDLE

AG AH AJ AK AL AM

●

●

IDLING VIBRATION

ROUGH IDLE/HUNTING

LOW IDLE

HI IDLE

AF

Fuel cut

AE

q q

Injec- Advanced tion timing Retarded

POOR ACCELERATION

LACK OF POWER

SPARK KNOCK/DETONATION

AC AD

Can be detected by CONSULT-II?

AB

HESITATION/SURGING/FLAT SPOT

WHEN DECELERATING

DURING DRIVING

AT IDLE

HARD TO START WHEN ENGINE IS HOT

HARD TO START WHEN ENGINE IS COLD

AA

Malfunction indicator illuminates.

New CT/CS

NO START (without first firing)

NO START (with first firing)

SYSTEM — Basic engine control system

ENGINE STALL

HARD/NO START/RESTART (EXCP. HA)

SYMPTOM

●

EC-CD-118

●

EMsection

*3

EC-CD-129 q

MAsection

*4

HARD TO START WHEN ENGINE IS COLD

Malfunction

SYSTEM — Engine control module system

EC-48

Engine control module

open, short

HARD TO START WHEN ENGINE IS HOT

open, short open, short

Accelerator position sensor circuit

Crankshaft position sensor (TDC) circuit noise

open, short

Fuel temperature sensor circuit

short

open, ground short

open, short

ground short

open, short

short

open, ground short

Control sleeve position sensor circuit

Fuel cut solenoid valve circuit

HESITATION/SURGING/FLAT SPOT

open, short

q

q

q q q

q q q q

q

q

q

q

q q

q q q

q q

q q q

q q q

LACK OF POWER

Vehicle speed sensor circuit or ABS actuator and electric unit (control unit) circuit

HI IDLE q

q

ROUGH IDLE/HUNTING

Needle lift sensor circuit

WHEN DECELERATING q

IDLING VIBRATION

q q

q q

q q

q

q

q

q

HA q

q

q q

q q

q q

q

q q q

q q q

q q

q q

q q

q q

q q q

q q q

q

q q

Malfunction indicator illuminates.

Injection timing control valve circuit

NO START (without first firing) AP

Fuel cut

Electric governor circuit

AT IDLE q

SLOW/NO RETURN TO IDLE

q

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

open, short

EXCESSIVE FUEL CONSUMPTION

AG AH AJ AK AL AM

BLACK SMOKE

NO START (with first firing) q

LOW IDLE

AF

EXCESSIVE OIL CONSUMPTION

short

POOR ACCELERATION

AE

WHITE SMOKE

q q

ABNORMAL SMOKE COLOR

q

EC-CD-114

EC-CD-108

Compensation for amount fuel injected according EC-CD-104 of to fuel temperature does not function.

EC-CD-100 Engine runs on after turning ignition switch OFF.

EC-CD-97

Injection timing cannot be EC-CD-82 controlled.

EC-CD-78

EC-CD-74

EC-CD-70

Compensation according to EC-CD-66 engine coolant temperature does not function.

EC-CD-62

Feature of symptom Check point

Engine coolant temperature sensor circuit

SPARK KNOCK/DETONATION

AC AD

Can be detected by CONSULT-II?

Mass air flow sensor circuit

HARD/NO START/ RESTART (EXCP. HA) DURING DRIVING AB

Reference page

open, ground short

DEAD BATTERY (UNDER CHARGE)

AA

ENGINE STALL

New CT/CS

SYMPTOM

TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart (Cont’d) CD20T

SYSTEM — Engine control module system

EC-49

Engine control module

ECM, Connector circuit

Brake switch circuits

Malfunction open short open, short

short

open

NO START (with first firing)

Air conditioner relay circuit

NO START (without first firing)

short

HARD TO START WHEN ENGINE IS COLD

Engine control module relay (Selfshutoff) circuit

HARD TO START WHEN ENGINE IS HOT q q q

q

q q q q q q q q q q q q q

q q q q

HESITATION/SURGING/FLAT SPOT

Glow relay circuit

LACK OF POWER

EGRC-solenoid valve circuit

HI IDLE

Power supply for ECM circuit

ROUGH IDLE/HUNTING

q q q

IDLING VIBRATION

q

SLOW/NO RETURN TO IDLE

q

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

q q

EXCESSIVE FUEL CONSUMPTION

q

BLACK SMOKE

open short open short open, short ground short open short open

WHEN DECELERATING q

WHITE SMOKE HA

q q q q q q

q q

q q EC-CD-108 Accelerator position sensor NG signal is output.

EC-CD-145 Start control does not function. Air conditioner does not stop EC-CD-126 operating. Air conditioner does not work.

EC-CD-59 Engine does not stop. q q EC-CD-59 q q EC-CD-129 q q Does not stop operating. q q Glow lamp does not turn on. EC-CD-118 q Glow lamp does not turn off. q EC-CD-59 Ground short makes engine q q q unable to stop. Air conditioner does not operate. EC-CD-126 Air conditioner does not stop q operating. q EC-CD-136 q q q q q q q q q q q q q EC-CD-86

AP

Fuel cut

Ignition switch circuit (ON signal)

AT IDLE q

EXCESSIVE OIL CONSUMPTION

AG AH AJ AK AL AM

ABNORMAL SMOKE COLOR

short

LOW IDLE

AF

Malfunction indicator illuminates.

Accelerator position switch (Idle) circuit

POOR ACCELERATION

AE

Can be detected by CONSULT-II?

short open, ground short

SPARK KNOCK/DETONATION

AC AD

Reference page

Air conditioner switch circuit

DURING DRIVING AB

DEAD BATTERY (UNDER CHARGE)

AA q q

Feature of symptom Check point

open, ground short

HARD/NO START/ RESTART (EXCP. HA)

open, short

ENGINE STALL

New CT/CS Start signal circuit

SYMPTOM

TROUBLE DIAGNOSIS — General Description Symptom Matrix Chart (Cont’d) CD20T

TROUBLE DIAGNOSIS — General Description

CD20T

CONSULT-II Reference Value in Data Monitor Mode Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. MONITOR ITEM

CONDITION

SPECIFICATION

CKPS⋅RPM (TDC)

●

CKPS⋅RPM-PUMP

●

Tachometer: Connect Almost the same speed as the CONRun engine and compare tachometer indication with the CONSULT-II value. SULT-II value.

COOLAN TEMP/S

●

Engine: After warming up

More than 70°C (158°F)

●

Turn drive wheels and compare speedometer indication with the CONSULT-II value

Almost the same speed as the CONSULT-II value

●

Engine: After warming up

More than 40°C (104 °F)

●

Ignition switch: ON (Engine stopped)

Accelerator pedal: release

Approx. 0.40V

Accelerator pedal: depress

Approx. 3.3V

Ignition switch: ON (Engine stopped)

Accelerator pedal: release

ON

Accelerator pedal: slightly open

OFF

VHCL SPEED SE FUEL TEMP SEN ACCEL POS SEN

OFF ACCEL POS

●

C/SLEEV POS/S

●

Engine: After warming up

BATTERY VOLT

●

Ignition switch: ON (Engine stopped)

11 - 14V

START SIGNAL

●

Ignition switch: ON , START , ON

OFF , ON , OFF

●

Engine: After warming up, idle the engine

AIR COND SIG IGN SW

MAS AIR/FL SE

●

Ignition switch: ON , OFF

●

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load

● ● ● ● ●

ACT INJ TIMG

● ● ●

●

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level

●

Ignition switch: ON

● ●

TARGET F/INJ

● ●

BRAKE SW

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level

Approx. 2.5V

Air conditioner switch: “OFF”

OFF

Air conditioner switch: “ON” (Compressor operates.)

ON ON , OFF

Idle

0.8 - 2.7V

2,000 rpm

2.2 - 2.8V

Idle

-0.5 to -1.5°

2,000 rpm

+2.5° to +3.5°

Idle

8.0 - 8.8 mm3/stroke

2,000 rpm

Approx. 7.6 mm3/stroke

Brake pedal: released

OFF

Brake pedal: depressed

ON

Brake pedal: released

OFF

BRAKE SW 2

●

Ignition switch: ON

FUEL CUT S/V

●

Ignition switch: ON , OFF

ON , OFF

AIR COND RLY

●

Air conditioner switch: OFF , ON

OFF , ON

GLOW RLY

●

Refer to EC-CD-124.

●

When cooling fan is stopped.

OFF

●

When cooling fan operates at low speed.

LOW

●

When cooling fan operates at high speed.

HI

●

Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load At sea level

COOLING FAN

●

EGRC SOL/V A

● ● ●

Brake pedal: depressed

ON

Idle

OFF

2,800 rpm

ON

EC-50

TROUBLE DIAGNOSIS — General Description

CD20T

Major Sensor Reference Graph in Data Monitor Mode The following are the major sensor reference graphs in “DATA MONITOR” mode. (Select “HI SPEED” in “DATA MONITOR” with CONSULT-II.)

ACCEL POS SEN, C/SLEEV POS/S, ACT INJ TIMG

-00”09 +04”95

Below is the data for “ACCEL POS SEN”, “C/SLEEV POS/S” and “ACT INJ TIMG” when revving engine quickly up to 3,000 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary.

x0.1V

● “ACCEL POS SEN” should increase

-00”09 +04”95

16:06

while depressing the accelerator pedal and should decrease while releasing it.

x0.1V

● “C/SLEEV POS/S” should increase

-00”09 +04”95

16:06

when depressing the accelerator pedal and should decrease when the pedal is released.

● “ACT INJ TIMG” should increase

ACT INJ TIMG 13:22

when depressing the accelerator pedal and should decrease when the pedal is released.

NEF780

EC-51

TROUBLE DIAGNOSIS — General Description

CD20T

ECM Terminals and Reference Value PREPARATION The ECM is located beneath the heater unit. To access the ECM, remove the center console under cover at the passenger side. Perform all voltage measurements with all connectors connected. Since the ECM harness connector cannot be accessed from the backside, voltages should be measured by connecting a break out box (SST) between ECM and ECM harness connector. SEF883Y

When measuring: ● Use extreme care not to touch 2 pins at the same time. ● Note that the data is for comparison and may not be exact. ● Be sure ECM unit is properly grounded before checking.

ECM

Y-adapter

Breakout box

To ECM harness connector Y-adapter

NEF162A

EC-52

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

ECM INSPECTION TABLE Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERWIRE MINAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage and Pulse Signal) qApproximately 10.5V

Engine is running. (Warm-up condition) Idle speed

101 102 103

SEF562S

B/L

Electric governor ground Approximately 10.5

Engine is running. (Warm-up condition) Engine speed is 2,000 rpm

SEF563S

104 105 106

B

107 108 109

R

Engine is running. ECM ground Idle speed

Power supply for ECM

Ignition switch “ON”

Engine ground (Probe this terminal with @ tester probe when measuring.) BATTERY VOLTAGE (11 - 14V) Approximately 9V

Engine is running. (Warm-up condition) Idle speed

202

B/W

SEF564S

Injection timing control valve

Approximately 8V

Engine is running. (Warm-up condition) Engine speed is 2,000 rpm

SEF565S

EC-53

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

TERWIRE MINAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage and Pulse Signal)

Engine is running.

204

L/W

Air conditioner relay

Both A/C switch and blower switch are “ON” Engine is running. A/C switch is “OFF” Engine is running. (Warm-up condition) Idle speed

208

P

Approximately 0.4V

BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V)

EGRC-solenoid valve A Engine is running. (Warm-up condition) Approximately 0.3V Engine speed is 2,800 rpm

214

215

W/R

OR/L

Glow relay

Malfunction indicator

Refer to “Glow control System”. Ignition switch “ON”

Approximately 1.0V

Engine is running.

BATTERY VOLTAGE (11 - 14V)

Idle speed 218

OR

Mass air flow sensor ground

Engine is running. Approximately 0V Idle speed Engine is running.

219

LG/R

Cooling fan relay (Low speed)

Cooling fan is not operating.

BATTERY VOLTAGE (11 - 14V)

Engine is running. Approximately 0.4V Cooling fan is operating. Engine is running.

220

LG

Cooling fan relay (High speed)

Cooling fan is not operating. Cooling fan is operating at low speed.

BATTERY VOLTAGE (11 - 14V)

Engine is running. Approximately 0.5V Cooling fan is operating at high speed. Ignition switch “ON” Approximately 1.0V Glow lamp is “ON”. 221

P/L

Glow lamp Ignition switch “ON” Glow lamp is “OFF”

223

W/L

Mass air flow sensor power supply

Ignition switch “ON”

BATTERY VOLTAGE (11 - 14V) Approximately 5V

Engine is running. (Warm-up condition) 1.9 - 2.3V Idle speed 224

L/W

Mass air flow sensor Engine is running. (Warm-up condition) 2.5 - 2.9V Engine speed is 2,000 rpm

EC-54

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

TERWIRE MINAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage and Pulse Signal) Approximately 2.6V

320

W

Control sleeve position sensor power supply

Engine is running. Idle speed

SEF559S

Approximately 2.6V

321

B

Control sleeve position sensor ground

Engine is running. Idle speed

SEF560S

Approximately 2.6V

322

R

Control sleeve position sensor (Reference signal)

Engine is running. (Warm-up condition) Idle speed

SEF561S

Engine is running. Ignition switch “LOCK” 325

W/G

Engine control module relay (Self-shutoff)

0 - 1V

For a few seconds after turning ignition switch to the “LOCK” position Ignition switch “LOCK” Following a few seconds delay after turning ignition switch to the “LOCK” position

331

OR

Crankshaft position sensor (TDC) ground

333

B

Needle lift sensor ground

334 335 436

B

Sensors’ ground

BATTERY VOLTAGE (11 - 14V)

Engine is running. Approximately 0V Idle speed Ignition switch “ON”

Approximately 0V

Engine is running. Approximately 0V Idle speed

EC-55

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

TERWIRE MINAL COLOR NO.

ITEM

CONDITION

DATA (DC Voltage and Pulse Signal) Approximately 0V

Engine is running. (Warm-up condition) Idle speed

344

W

NEF867

Crankshaft position sensor (TDC) (Signal)

Approximately 0V

Engine is running. Engine speed is 2,000 rpm

NEF868

Approximately 3.8 - 4.0V

Engine is running. (Warm-up condition) Idle speed

NEF869

345

W

Needle lift sensor Approximately 3.8 - 4.0V

Engine is running. (Warm-up condition) Engine speed is 2,000 rpm

NEF870

347

L/B

Engine coolant temperature sensor

348 411

R/Y

Fuel temperature sensor

349

SB

Engine is running.

0.6 - 4.8V Output voltage varies with engine coolant temperature.

Engine is running.

0.6 - 4.8V Output voltage varies with fuel temperature.

Ignition switch “LOCK”

Approximately 0V

Ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

Fuel cut solenoid valve

EC-56

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

TERWIRE MINAL COLOR NO.

ITEM

DATA (DC Voltage and Pulse Signal)

CONDITION

Engine is running.

403

GY

Air conditioner switch

Both air conditioner switch and blower switch are “ON” (Compressor operates) Engine is running. Air conditioner switch is “OFF”

Approximately 0V

BATTERY VOLTAGE (11 - 14V)

Ignition switch “ON” 0V Brake pedal released 405

R/G

Stop lamp switch Ignition switch “ON” Brake pedal depressed

410

OR

Immobilizer communication

Ignition switch “ON” Ignition switch “ON” Brake pedal released

416

R/B

Battery voltage (11 - 14V) BATTERY VOLTAGE (4 - 14V) Battery voltage (11 -14V)

Brake switch 2 Ignition switch “ON” 0V Brake pedal depressed 0 - Approximately 4.2V

417

OR/W

Vehicle speed sensor or ABS actuator and electric unit (control unit)

Engine is running. Lift up the vehicle. In 2nd gear position Vehicle speed is 40 km/h (25 mph)

SEF552S

420

BR/W

415

G/R

425

BR

433

LG/W

Engine is running. Data link connector for CONSULT-II

Accelerator position sensor ground Accelerator position sensor power supply

Idle speed (CONSULT-II is connected and turned on)

Approximately 4 - 9V Approximately 0V

Engine is running. Approximately 0V Idle speed Ignition switch “ON”

Approximately 5V

Ignition switch “ON” 0.4 - 0.6V 434

W/PU

Accelerator position sensor

Accelerator pedal released Ignition switch “ON” Approximately 4.0V Accelerator pedal fully depressed

EC-57

CD20T TROUBLE DIAGNOSIS — General Description ECM Terminals and Reference Value (Cont’d)

TERWIRE MINAL COLOR NO.

ITEM

DATA (DC Voltage and Pulse Signal)

CONDITION

Ignition switch “ON” Approximately 0V 435

GY/R

Accelerator position switch (Idle)

Accelerator pedal released Ignition switch “ON” Approximately 2.7V Accelerator pedal depressed

442

B/Y

Ignition switch “ON”

Approximately 0V

Ignition switch “START”

BATTERY VOLTAGE (11 - 14V)

Start signal

Approximately 1.1 - 1.5V

Engine is running. (Warm-up condition) Idle speed

SEF550S

439

L/OR

Tachometer Approximately 1.1 - 1.5V

Engine is running. Engine speed is 2,000 rpm

SEF551S

507

BR/Y

Ignition switch “LOCK”

0V

Ignition switch “ON”

BATTERY VOLTAGE (11 - 14V)

Ignition switch

EC-58

TROUBLE DIAGNOSIS FOR POWER SUPPLY

CD20T

Main Power Supply and Ground Circuit

YEC100A

EC-59

CD20T TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) INSPECTION START

H

No

Start engine. Is engine running?

E

Yes

NEF863

H

1. Stop engine. 2. Disconnect ECM harness connector. 3. Turn ignition switch to “ON” position.

ECM relay

YEC327

CHECK POWER SUPPLY-I. 1. Disconnect ECM harness connector. 2. Turn ignition switch to “ON” position. 3. Check voltage between ECM connector terminal 507 and ground Voltage: Battery voltage If NG, check the following: ● 10A fuse ● Harness connectors M52 , F103 ● Harness for open or short-circuit between ECM and ignition switch. If NG, replace 10A fuse or repair harness or connectors. OK

F H

CHECK POWER SUPPLY-II. 1. Short between ECM connector terminal 325 and engine ground with a jump wire. 2. Check voltage between ECM terminals 107 , 108 , 109 and ground. Voltage: Battery voltage

OK E

“CHECK Go to GROUND CIRCUIT” on page EC-CD-61.

E

Check the following: ● Harness connectors M89 , F96 ● Harness for open or short-circuit between ECM relay and ECM. If NG, repair harness or connectors.

NG H NEF186A

CHECK HARNESS CONTINUITY BETWEEN ENGINE CONTROL MODULE RELAY AND ECM Check harness continuity between ECM connector terminals 107 , 108 , 109 and ECM relay connector terminal p 5 . Continuity should exist. If OK, check harness for short. H OK

A p

NEF187A

ECM relay connector

NEF188A

EC-60

NG

CD20T TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) A p

ECM relay connector

H

CHECK VOLTAGE BETWEEN ENGINE CONTROL MODULE RELAY AND GROUND. Check voltage between ECM relay connector terminals p 2 , p 3 and ground with CONSULT-II or tester. Voltage: Battery voltage

NG E

Check the following: ● 15A fuse ● Harness for open or short-circuit between ECM relay and battery. If NG, replace fuse or repair harness or connectors.

E

Check harness connectors E43 , F2 Repair harness or connectors.

E

Replace ECM relay.

E

Repair harness or connectors.

YEC352

OK H

CHECK OUTPUT SIGNAL CIRCUIT. Check harness continuity between ECM connector terminal 325 and ECM relay connector terminal p 1 . Continuity should exist. If OK, check harness for short-circuit.

ECM relay connector

NG

●

OK H NEF189A

ECM relay connector

CHECK ECM RELAY. 1. Apply 12V direct current between ECM relay connector terminals p 1 and p 2 . 2. Check continuity between engine control module relay connector terminals p 3 and 5 . p 12V (p 1 -p 2 ) applied: Continuity exists. No voltage applied: No continuity

NG

OK H

YEC354

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between ECM connector terminals 104 , 105 , 106 and engine ground. Continuity should exist. If resistance is too high, loosen, clean and retighten engine ground. If OK, check harness for short-circuit. H

OK

Check ECM pin terminals for damage and check the connection of ECM harness connector. NEF190A

H

INSPECTION END

Engine ground NEF399

EC-61

NG

CD20T

TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS)

The mass air flow sensor measures the amount of intake air by analysing a part of the entire flow. When intake air flows into the intake manifold, heat is withdrawn from the hot film. By regulating the electrical current that flows through the hot film, the ECM maintains the hot film temperature on a constant level. The amount of electric current that is needed to keep the hot film on a constant temperature level is proportional to the mass of air that flows into the engine. NEF663

Check Items (Possible Cause)

Malfunction is detected when . . . ●

An excessively high or low voltage from the sensor is entered to ECM.

●

●

Harness or connectors (The sensor circuit is open or shorted.) Mass air flow sensor

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait for at least 20 seconds.

EC-62

CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d) BATTERY : Detectable line for DTC : Non-detectable line for DTC

Refer to EL-POWER.

ENGINE CONTROL MODULE RELAY

MASS AIR FLOW SENSOR

ECM

YEC799

EC-63

CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d) Mass air flow sensor harness connector

DIAGNOSTIC PROCEDURE INSPECTION START

H

NEF788

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect mass air flow sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between mass air flow sensor connector terminal p 2 and ground. Voltage: Battery positive voltage

NG E

Repair harness or connectors.

E

Repair harness or connectors.

E

Repair harness or connectors.

E

Replace mass air flow sensor.

OK Mass air flow sensor connector

NEF789

H

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between mass air flow sensor connector terminal p 3 and ECM connector terminal 218 . Continuity should exist. If OK, check harness for short-circuit.

NG

OK H

Mass air flow sensor connector

CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between mass air flow sensor connector terminal p 4 and ECM connector terminal 223 , mass air flow sensor connector terminal p 5 and ECM connector terminal 224 . Continuity should exist. If OK, check harness for short.

NG

OK NEF191A H

Mass air flow sensor connector

CHECK COMPONENT (Mass air flow sensor). Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuits. Then retest. Trouble is not fixed. NEF192A

H

Check ECM pin terminals for damage or the connection of ECM harness connector.

H

INSPECTION END

EC-64

NG

CD20T TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor (MAFS) (Cont’d)

COMPONENT INSPECTION Mass air flow sensor

Mass air flow sensor connector

1. Turn ignition switch to “ON” position. 2. Start engine and warm it up sufficiently. 3. Check voltage between mass air flow sensor connector terminal p 5 and ground. Conditions Ignition switch “ON” position (Engine stopped.) NEF792

Idle (Engine is warmed-up sufficiently.)

Voltage V Approximately 1.0 1.9 - 2.3

4. If NG, remove mass air flow sensor from air duct. Check hot film for damage or dust.

NEF669

EC-65

CD20T

TROUBLE DIAGNOSIS 2

Engine Coolant Temperature (ECT) Sensor The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. SEF594K

Engine coolant temperature °C (°F)

Voltage (V)

Resistance (kΩ)

−10 (14)

4.4

7.0 - 11.4

20 (68)

3.5

2.1 - 2.9

50 (122)

2.3

0.68 - 1.00

90 (194)

1.0

0.236 - 0.260

SEF012P

Check Items (Possible Cause)

Malfunction is detected when ... ●

An excessively high or low voltage from the sensor is entered to ECM.

●

●

Harness or connectors (The sensor circuit is open or shorted.) Engine coolant temperature sensor

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.

EC-66

CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d)

ENGINE COOLANT TEMPERATURE SENSOR

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC800

EC-67

CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d) .

DIAGNOSTIC PROCEDURE

RH strut tower

INSPECTION START

H .

Engine coolant temperature sensor harness connector

NEF401

Engine coolant temperature sensor connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect engine coolant temperature sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between engine coolant temperature sensor connector terminal p 2 and ground with CONSULT-II or tester. Voltage: Approximately 4.9V

NG

E

Repair harness or connectors.

E

Repair harness or connectors.

E

Replace engine coolant temperature sensor.

OK H NEF193A

Engine coolant temperature sensor connector

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between engine coolant temperature sensor connector terminal p 1 and engine ground. Continuity should exist. If OK, check harness for short-circuit.

NG

OK H SEF542P

CHECK COMPONENT (Engine coolant temperature sensor). Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.

H

INSPECTION END

EC-68

NG

CD20T TROUBLE DIAGNOSIS 2 Engine Coolant Temperature (ECT) Sensor (Cont’d)

COMPONENT INSPECTION Engine coolant temperature sensor Check resistance as shown in the figure.

SEF152P

Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.0

90 (194)

0.236 - 0.260

If NG, replace engine coolant temperature sensor.

SEF012P

EC-69

CD20T

TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS)

Models with vehicle speed sensor The vehicle speed sensor is installed in the transaxle. It contains a pulse generator which provides a vehicle speed signal to the speedometer. The speedometer then sends a signal to the ECM.

Vehicle speed sensor

Models without vehicle speed sensor The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the speedometer. The speedometer than sends a signal to the ECM. AEC110

Check Items (Possible Cause)

Malfunction is detected when .... ●

The almost 0 km/h (0 mph) signal from vehicle speed sen- Models with vehicle speed sensor sor or ABS actuator and electric unit (control unit) is sent ● Harness or connector to ECM even when vehicle is being driven. (The vehicle speed sensor circuit is open or shorted.) ● Vehicle speed sensor Models without vehicle speed sensor ● Harness or connector (The ABS actuator and electric unit (control unit) is open or shorted.) ● ABS actuator and electric unit (control unit)

OVERALL FUNCTION CHECK

PEF651U

Use this procedure to check the overall function of the vehicle speed sensor circuit. During this check, a DTC might not be confirmed. 1) Jack up drive wheels. 2) Start engine. 3) Read vehicle speed sensor signal in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should be able to exceed 10 km/h (6 mph) when rotating wheels with suitable gear position. ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------1) Jack up drive wheels. 2) Start engine. 3) Rotate drive wheel by hand. 4) Check voltage between ECM connector terminal 417 and ground with voltage tester. Voltage should vary between approx. 0 - 0.6V.

NEF194A

EC-70

TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)

CD20T

MODELS BEFORE VIN - P11U0583350 BATTERY

IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

Refer to EL-POWER.

: Dectable line for DTC : Non-detectable line for DTC

COMBINATION METER (SPEEDOMETER)

VEHICLE SPEED SENSOR

ECM

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEC801

EC-71

TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)

CD20T

MODELS AFTER VIN - P11U0583350

YEC101A

EC-72

TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor (VSS) (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE INSPECTION START

H

CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and combination meter harness connector. 3. Check harness continuity between ECM connector terminal 417 and combination meter connector terminal p 9 or p 4 . Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and combination meter. If NG, repair harness or connectors.

OK YEC124A

H

CHECK SPEEDOMETER FUNCTION. Make sure that speedometer functions correctly. OK

H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.

H

INSPECTION END

EC-73

NG

E

Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between combination meter and vehicle speed sensor or ABS actuator and electric unit (control unit). If NG, repair harness or connectors. Check vehicle speed sensor or ABS actuator and electric unit (control unit) and its circuit. Refer to EL section.

CD20T

TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS)

The control sleeve position sensor is installed on the electric governor. It senses the position of control sleeve (rotor angle) while the control sleeve is being driven by the electric governor, and feeds it back to the ECM.

Shaft

Sensor coil SEF641S

Check Items (Possible cause)

Malfunction is detected when .... An excessively high or low voltage from the sensor is detected by ECM. ............................................................................................... ● An incorrect voltage signal from the sensor is detected by ECM during engine running. ●

.

●

●

Harness or connectors (The control sleeve position sensor circuit is open or shorted.) Control sleeve position sensor

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE

Electronic injection pump harness connector (control sleeve position sensor)

1) 2)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 2 seconds at idle speed.

NEF796

EC-74

CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d) INJECTION PUMP (CONTROL SLEEVE POSITION SENSOR)

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC802

EC-75

CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d)

DIAGNOSTIC PROCEDURE Control sleeve position sensor connector

INSPECTION START

H

NEF196A

Control sleeve position sensor connector

CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between control sleeve position sensor connector terminal 3 and ECM connector terminal 320 . p Continuity should exist. If OK, check harness for short-circuit.

NG E

Repair harness or connectors.

E

Repair harness or connectors.

E

Repair harness or connectors.

E

Have the injection pump assembly serviced by an authorised service representative.

OK H

NEF197A

CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between control sleeve position sensor connector terminal 2 and ECM terminal 321 . p Continuity should exist. If OK, check harness for short-circuit.

NG

OK H Control sleeve position sensor connector

CHECK REFERENCE SIGNAL CIRCUIT. Check harness continuity between control sleeve position sensor connector terminal 1 and ECM connector terminal 322 . p Continuity should exist. If OK, check harness for short-circuit.

NG

OK H NEF198A

CHECK COMPONENT (Control sleeve position sensor). Refer to “COMPONENT INSPECTION” on next page. H

OK

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed.

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-76

NG

CD20T TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor (CSPS) (Cont’d)

COMPONENT INSPECTION Control sleeve position sensor, electric governor & fuel temperature sensor connector

Control sleeve position sensor 1. Disconnect electronic injection pump harness connector. 1 and p 3 , p 2 and 2. Check continuity between terminals p 3 . p Resistance: Approximately 6.0Ω [at 25°C (77°F)] If NG, take proper action.

NEF680

EC-77

CD20T

TROUBLE DIAGNOSIS 5 Electric Governor Return spring

Coil Rotor

Core Shaft Ball pin

The electric governor is built into the fuel injection pump. It moves the control sleeve to increase or decrease the amount of fuel injected. When current flows through the coil, a magnetic force is produced, rotating the rotor. The rotor shaft is installed to the control sleeve via a ball pin which is eccentrically situated in relation to the rotor shaft. With this arrangement, the control sleeve can be moved in relation to rotor rotation. The rotor’s rotating angle is determined by a balanced condition of magnetic force (generated by current flow regulated by means of the ECM) and tension of return spring (installed to rotor). The larger the current flow through the coil, the greater the rotor’s rotating angle. This means that the control sleeve moves to the right, increasing the amount of fuel injected. The ECM regulates the current flow through the coil by changing the duty cycle ratio which controls the ON-OFF operation of the electric governor grounding circuit.

Decrease Increase Control sleeve SEF632S Magnet

Core

Rotor Coil SEF633S

Check Items (Possible cause)

Malfunction is detected when .... ●

Fuel injection feedback system does not operate properly. [This system consists essentially of ECM, electric governor and control sleeve position sensor.]

●

●

● ●

Main power supply circuit (ECM connector terminals 107 , 108 , 109 ) and fuse Harness or connectors (Electric governor and control sleeve position sensor circuit) Electric governor ECM

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine above 1,200 rpm. Run it for 2 seconds above 1,200 rpm. Return engine speed to idle.

NOTE: If malfunction occurs intermittently, conduct suitable driving pattern for 10 minutes. This makes it possible to determine the diagnostic trouble.

EC-78

TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d)

CD20T

BATTERY : Detectable line for DTC : Non-detectable line for DTC

Refer to EL-POWER.

INJECTION PUMP (ELECTRIC GOVERNOR)

ENGINE CONTROL MODULE RELAY

ECM

YEC803

EC-79

CD20T

TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START H

CHECK MAIN POWER SUPPLY. Refer to EC-CD-59. .

Electronic injection pump harness connector (Electric governor) NEF800

Injection pump connector

NEF199A

H

CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between injection pump connector terminal 7 and ECM connector terminals p 107 , 108 , 109 . Continuity should exist. If OK, check harness for short-circuit.

NG

E

Repair harness or connectors.

E

Repair harness or connectors.

OK H

CHECK GROUND CIRCUIT. Check harness continuity between injection pump connector terminal p 4 and ECM connector terminals 101 , 102 , 103 . Continuity should exist. If OK, check harness for short-circuit.

Injection pump connector

NG

OK

NEF200A H

CHECK COMPONENT (Electric governor). Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed.

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-80

NG

E

Have the injection pump assembly serviced by an authorised service representative.

TROUBLE DIAGNOSIS 5 Electric Governor (Cont’d)

CD20T

COMPONENT INSPECTION Electric governor Electronic injection pump harness connector

1. Disconnect electronic injection pump harness connector. 2. Check continuity between injection pump connector terminals p 4 and p 7 . Resistance: Approximately 1.0Ω [at 25°C (77°F)] If NG, replace.

YEC361

EC-81

CD20T

TROUBLE DIAGNOSIS 6 Injection Timing Control Valve

Timer piston

High pressure

Low pressure

Fuel injection timing control valve SEF638S

The injection timing control valve is built into the fuel injection pump. It controls the timer piston to change the fuel injection timing. The timing control valve is a solenoid valve located in the line between high-pressure chamber and low-pressure chamber. It changes fuel pressure in the high-pressure chamber. When current flows through the solenoid (the solenoid turns ON), the timing control valve opens, advancing fuel injection timing. When current does not flow through it, the timing control valve closes, retarding injection timing. The ECM emits an ON-OFF duty cycle signal. The longer the OFF-duration, the greater the advance angle. The longer the ON-duration, the greater the retard angle. This means that changing the ON-OFF duty cycle ratio makes it possible to achieve an optimal advance angle and accurately control fuel injection timing. Check Items (Possible cause)

Malfunction is detected when .... ●

Injection timing feedback system does not operate properly. (This system consists essentially of ECM, injection timing control valve and needle lift sensor.)

●

● ● ● ● ●

Injection timing control valve circuit it open or shorted.

●

●

Harness or connectors [Injection timing control valve, needle lift sensor, crankshaft position sensor (TDC) circuits] Injection timing control valve Needle lift sensor Crankshaft position sensor (TDC) Air in fuel line Harness or connectors (The Injection timing control valve is open or shorted.) Injection timing control valve

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL SYSTEM 1)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine. Run engine for 10 seconds at idle.

2) NOTE: If malfunction occurs intermittently, conduct suitable driving pattern for 10 minutes. This makes it possible to determine the diagnostic trouble.

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL VALVE CIRCUIT 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.

EC-82

CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d) BATTERY Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC

ENGINE CONTROL MODULE RELAY

INJECTION PUMP (INJECTION TIMING CONTROL VALVE)

ECM

YEC804

EC-83

CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d)

DIAGNOSTIC PROCEDURE Priming pump

INSPECTION START

H

SEF671S

CHECK FOR AIR IN FUEL FILTER. 1. Move priming pump up and down to purge air from fuel filter. 2. Perform “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”.

H

Fuel injection timing control valve harness connector

NEF804

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect injection timing control valve harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between injection timing control valve connector terminal 3 and ground with CONSULT-II or p tester. Voltage: Battery voltage

Injection timing control valve harness connector

NG

E

OK

Check the following: ● Harness connectors E89 , F96 ● Electronic injection pump harness connector F49 ● 15A fuse ● Harness for open or short-circuit between injection timing control valve harness connector and ECM relay. If NG, repair harness or connectors.

H

NEF201A

Injection timing control valve harness connector

CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between injection timing control valve connector terminal p 2 and ECM terminals 202 . Continuity should exist. If OK, check harness for short-circuit. H

NEF202A

A p

EC-84

OK

NG

E

Check the following: ● Electronic injection pump harness connector F49 ● Harness for open or short-circuit between injection timing control valve and ECM. If NG, repair harness or connectors.

CD20T TROUBLE DIAGNOSIS 6 Injection Timing Control Valve (Cont’d) A p

H

CHECK COMPONENT (Injection timing control valve). Refer to “COMPONENT INSPECTION” below.

NG

E

Replace injection timing control valve.

OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed.

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

COMPONENT INSPECTION Injection timing control valve 1. Disconnect injection timing control valve harness connector. 2 and p 3 . 2. Check resistance between terminals p Resistance: Approximately 15Ω [at 25°C (77°F)] If NG, replace injection timing control valve.

Injection timing control valve

YEC364

EC-85

CD20T

TROUBLE DIAGNOSIS 7 Engine Control Module (ECM)

The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The module monitors and controls the engine operation.

SEC220B

Check Item (Possible Cause)

Malfunction is detected when .... ●

ECM calculation function is malfunctioning.

●

ECM *

●

An excessively high or low voltage from the atmospheric pressure sensor is detected by the ECM.

●

ECM *

●

ECM reference voltage (2.5V) is excessively high or low.

●

ECM *

●

ECM version number or switching function is not plausible.

●

ECM *

●

Ignition switch “ON” signal evaluation circuit in ECM is malfunctioning.

●

ECM *

* Actually inspecting the ECM inside circuit is impossible. Then, ECM may be replaced.

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.

EC-86

CD20T

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) SYSTEM DESCRIPTION Vehicle speed sensor

Vehicle speed

Engine coolant temperature sensor

Engine coolant temperature

Air conditioner switch

Air conditioner “ON” signal

E

E

ECM

E

Cooling fan relay(s)

E

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air conditioner system pressure and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/ OFF]. This system indirectly relates to diagnostic trouble code 28 (Overheat).

Operation Air conditioner is ON Engine coolant temperature °C (°F)

Engine coolant temperature °C (°F)

Air conditioner is OFF

.

102 (216) .

96 (205)

.

.

.

102 (216) 96 (205)

.

20 80 (12) (50) Vehicle speed km/h (mph) Cooling fans do not operate

.

20 (12)

.

80 (50)

Vehicle speed km/h (mph)

Cooling fans operate at low speed

Cooling fans operate at high speed

NEF772

ON-BOARD DIAGNOSIS LOGIC This diagnosis continuously monitors the engine coolant temperature. If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. Check Items (Possible Cause)

Malfunction is detected when ... ●

An excessive high engine coolant temperature sensor signal is detected by the ECM. (Overheat)

Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● Radiator hose ● Radiator ● Radiator cap ● Water pump ● Thermostat ● Fan belt ● Engine coolant temperature sensor For more information, refer to “12 MAIN CAUSES OF OVERHEATING”, EC-CD-95. ●

CAUTION: When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil. a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA section (“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”). b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

EC-87

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

OVERALL FUNCTION CHECK

MAX. OK MIN.

AEC640

SEF111X

SEC163BA

Cooling fan Engine coolant temperature sensor harness connector

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. 1) Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to “DIAGNOSTIC PROCEDURE”, EC-CD-90. 2) Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to “DIAGNOSTIC PROCEDURE”, EC-CD-90. 3) Turn ignition switch to “ON” position. 4) Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II (LOW speed and HI speed). ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------3) Start engine. Be careful not to overheat engine. 4) Set temperature control switch to full cold position. 5) Push Air Conditioner switch to “ON” position. 6) Turn blower fan switch to “ON” position. 7) Run engine at idle for a few minutes with Air Conditioner operating. Be careful not to overheat engine. 8) Make sure that both cooling fans operate at low speed. 9) Turn ignition switch to “LOCK” position. 10) Push Air Conditioner switch and blower fan switch to “OFF” position. 11) Disconnect engine coolant temperature sensor harness connector. 12) Connect 150Ω resistor to engine coolant temperature sensor harness connector. 13) Restart engine and make sure that both cooling fans operate at higher speed than low speed. Be careful not to overheat engine.

150Ω resistor

MEC475B

EC-88

CD20T

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) BATTERY

IGNITION SWITCH ON or START FUSE BLOCK (J/B)

Refer to EL-POWER. : Detectable line for DTC : Non-detectable line for DTC

COOLING FAN RELAY-3

COOLING FAN RELAY-1

COOLING FAN RELAY-2

COOLING FAN MOTOR-1

HIGH

TRIPLEPRESSURE SWITCH

COOLING FAN MOTOR-2

LOW

ECM

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEC805

EC-89

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE INSPECTION START .

Cooling fan relay 2 H

Cooling fan relay-3 Cooling fan relay-1

YEC383

SEF111X

NG CHECK COOLING FAN LOW SPEED OPERATION. 1. Disconnect cooling fan relay-3. 2. Turn ignition switch to “ON” position. 3. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. ------------------------------------------------------------- OR ------------------------------------------------------------2. Start engine. 3. Set temperature switch at full cold position. 4. Turn Air Conditioner switch to “ON” position. 5. Turn blower fan switch to “ON” position. 6. Run engine at idle speed for a few minutes with Air Conditioner operating. 7. Make sure that both cooling fans operate at low speed.

E

Check cooling fan low speed control circuit. (Go to PROCEDURE A .)

OK H

Cooling fan

NEF809

SEF111X

Cooling fan Engine coolant temperature sensor harness connector

NG CHECK COOLING FAN HIGH SPEED OPERATION. 1. Turn ignition switch to “LOCK” position. 2. Reconnect cooling fan relay-3. 3. Disconnect cooling fan relay-1. 4. Turn ignition switch to “ON” position. 5. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. ------------------------------------------------------------- OR ------------------------------------------------------------4. Turn Air Conditioner switch and blower fan switch to “OFF” position. 5. Disconnect engine coolant temperature sensor harness connector. 6. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 7. Restart engine and make sure that both cooling fans operate at higher speed than low speed. H

B p

OK

(Go to EC-CD-94.) resistor YEC384

EC-90

E

Check cooling fan high speed control circuit. (Go to PROCEDURE B .)

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

PROCEDURE A Cooling fan relay-1 connector

Cooling fan motor-1 connector

INSPECTION START

H

YEC385 .

Under the vehicle

.

A/C compressor

Cooling fan motor-1 harness connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-1 and fan motor-1 connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between cooling fan motor-1 connector terminal p 1 , fan 1 and relay-1 connector terminal p ground. Voltage: Battery voltage

NG

E

OK

NEF416 .

Under the vehicle

.

Radiator lower hose .

Cooling fan motor-2 harness connector

NEF417

Cooling fan motor-1 connector Cooling fan relay-1 connector

Cooling fan relay-2 connector

YEC386

Cooling fan relay-1 connector

Cooling fan motor-2 connector

Check the following: ● 10A fuse ● 40A, 100A, fusible links ● Harness for open or short-circuit between cooling fan motor-1 and battery. ● Harness for open or short-circuit between cooling fan relay-1 and fuse. If NG, replace fuse or fusible links or repair harness or connectors.

H

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-2 and fan motor-2 harness connector. 3. Check harness continuity between cooling fan relay-1 connector terminal p 5 and cooling fan relay-2 connector terminal 4 ; cooling fan motor-1 conp 2 and cooling nector terminal p fan relay-2 connector terminal 3 . Continuity should exist. p If OK, check harness for shortcircuit. 4. Check harness continuity between cooling fan motor-2 connector terminal p 1 and cooling fan relay-1 connector terminal p 3 ; cooling fan motor-2 connector terminal p 2 and ground. Continuity should exist. If OK, check harness for shortcircuit. H

C p

YEC387

EC-91

OK

NG

E

Repair harness or connectors.

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

C p

Cooling fan relay-1 connector

NEF207A

H

NG Check the following: CHECK OUTPUT SIGNAL CIRCUIT. E 1. Disconnect ECM harness connector. ● Harness connectors E43 , F2 2. Check harness continuity between ECM terminal 219 and cooling fan relay-1 con● Harness for open or short2 . nector terminal p circuit between cooling fan Continuity should exist. relay-1 and ECM If OK, check harness for short-circuit. If NG, repair harness or connectors. OK H

CHECK COMPONENT (Cooling fan relay-1, 2). Refer to “COMPONENT INSPECTION”, EC-CD-96. H

E

Replace cooling fan relay.

OK

CHECK COMPONENT (Cooling fan motors). Refer to “COMPONENT INSPECTION”, EC-CD-96. H

NG

NG E

Replace cooling fan motors.

OK

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed.

H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

PROCEDURE B

Cooling fan relay-3 connector

Cooling fan motor-1 connector

Cooling fan relay-2 connector

INSPECTION START

H

NEF203A

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan relay-2, 3 and cooling fan motor-1. 3. Turn ignition switch to “ON” position. 4. Check voltage between cooling fan motor-1 connector terminal p 1 ; cooling fan relay-2 connector terminal p 1 ; cooling fan relay-3 connector terminals p 1 & 3 and ground. p Voltage: Battery voltage OK H

D p

EC-92

NG E

Check the following: ● 10A-fuse ● 40A, 50A, 100A fusible links ● Harness for open or short-circuit between fan motor-1, fan relay-3 and fusible link or fan relay-2, 3 and fuse. If NG, replace fuse or fusible link or repair harness or connectors.

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

D p

H Cooling fan motor-1 connector

Cooling fan relay-2 connector

Cooling fan relay-3 connector

Cooling fan motor-2 connector

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect cooling fan motor-2 harness connector. 3. Check harness continuity between cooling fan motor-1 connector terminal p 2 and cooling fan relay-2 connector terminal p 3 ; cooling fan motor-2 connector terminal p 1 and cooling fan relay-3 connector terminal p 5 ; cooling fan relay-2 connector terminal p 5 and ground. Continuity should exist. If OK, check harness for short-circuit. 4. Check harness continuity between cooling fan motor-2 terminal p 2 and ground.

NG E

Repair harness or connectors.

OK H

NEF876

Cooling fan motor-2 connector E18

CHECK OUTPUT SIGNAL CIRCUIT. 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 220 and cooling fan relay-3 connector terminal p 2 & cooling fan relay-2 connector terminal p 2 . Continuity should exist. If OK, check harness for short-circuit. H

H

H

OK

Disconnect and reconnect harness connectors in the circuit. Then retest. Cooling fan relay-2 connector NEF204A

H

Trouble is not fixed

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-93

NG E

Check the following: ● Harness connectors E43 , F2 ● Harness for open or short-circuit between cooling fan relay-2, 3 and ECM. If NG, repair harness or connectors. Replace cooling fan relays.

OK

CHECK COMPONENTS (Cooling fan motors). Refer to “COMPONENT INSPECTION”, ECCD-96. Cooling fan relay-3 connector

E

OK

CHECK COMPONENT (Cooling fan relay-2, 3). Refer to “COMPONENT INSPECTION”, ECCD-96. YEC389

NG

NG E

Replace cooling fan motors.

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d)

CD20T

B p

Hose adapter

H

CHECK COOLING SYSTEM FOR LEAK. Apply pressure to the cooling system with a tester, and check if the pressure drops. Testing pressure: 157kPa (1.57 bar, 1.6 kg/cm2, 23 psi) Pressure should not drop. CAUTION: Higher than the specified pressure may cause radiator damage. .

SLC754AA

NG

E

Check the following for leaks: ● Hose ● Radiator ● Water pump Refer to LC section (“Water Pump”).

E

Replace radiator cap.

E

Replace thermostat.

E

Replace engine coolant temperature sensor.

OK H

CHECK RADIATOR CAP. Apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 - 88 kPa (0.59 - 0.88 bar, 0.6 - 0.9 kg/cm2, 9 - 13 psi)

NG

OK SLC755AA

SLC343

H

CHECK THERMOSTAT. 1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and maximum valve lift. Valve opening temperature: 76.5°C (170°F) [standard] Maximum valve lift: More than 8 mm/90°C (0.31 in/194°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to LC section (“Thermostat”). H

OK

Check engine coolant temperature sensor. Refer to “COMPONENT INSPECTION”, EC-69. H

NG

NG

OK

If the cause can not be isolated, go to “12 MAIN CAUSES OF OVERHEATING” on next page. H

INSPECTION END

Perform FINAL CHECK by the following procedure after repair is completed. 1. Warm up engine. Run the vehicle for at least 20 minutes. Pay attention to engine coolant temperature gauge on the instrument panel. If the reading shows an abnormally high temperature, another part may be malfunctioning. 2. Stop vehicle and let engine idle. Check the intake and exhaust systems for leaks by listening for noise or visually inspecting the components. 3. Allow engine to cool and visually check for oil and coolant leaks. Then, perform “OVERALL FUNCTION CHECK”.

EC-94

CD20T

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) 12 MAIN CAUSES OF OVERHEATING Engine

Step

OFF

1

Inspection item

Standard

●

2

●

Coolant mixture

●

Coolant tester

50 - 50% coolant mixture

3

●

Coolant level

●

Visual

Coolant up to MAX level See “Changing Engine in reservoir tank and Coolant”, “ENGINE radiator filler neck MAINTENANCE” in MA section.

4

●

Radiator cap

●

Pressure tester

78 - 98 kPa (0.78 - 0.98 bar, 0.8 1.0 kg/cm2, 11 - 14 psi) 59 - 98 kPa (0.59 - 0.98 bar, 0.6 1.0 kg/cm2, 9 - 14 psi) (Limit)

See “System Check” “ENGINE COOLING SYSTEM” in LC section.

ON*2

5

●

Coolant leaks

●

Visual

No leaks

See “System Check” “ENGINE COOLING SYSTEM” in LC section.

ON*2

6

●

Thermostat

●

Touch the upper and lower radiator hoses

Both hoses should be hot

See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM” in LC section.

ON*1

7

●

Cooling fan

●

CONSULT

Operating

See “TROUBLE DIAGNOSIS 8”.

OFF

8

●

Combustion gas leak

●

Color checker chemical tester 4 Gas analyzer

Negative

−

ON*3

9

●

Coolant temperature gauge

●

Visual

Gauge less than 3/4 when driving

−

●

Coolant overflow to reservoir tank

●

Visual

No overflow during driving and idling

See “Changing Engine Coolant”, “ENGINE MAINTENANCE” in MA section. See “ENGINE MAINTENANCE” in MA section.

● ●

●

Visual

No blocking

Reference page

Blocked Blocked Blocked Blocked

●

radiator condenser radiator grille bumper

Equipment

−

See “RECOMMENDED FLUIDS AND LUBRICANTS” in MA section.

OFF*4

10

●

Coolant return from reservoir tank to radiator

●

Visual

Should be initial level in reservoir tank

OFF

11

●

Cylinder head

●

Straight gauge feeler gauge

0.1 mm (0.004 in) Maxi- See “Inspection”, “CYLmum distortion (warping) INDER HEAD” in EM section.

12

●

Cylinder block and pistons

●

Visual

No scuffing on cylinder walls or piston

*1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 mph) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.

EC-95

See “Inspection”, “CYLINDER BLOCK” in EM section.

CD20T

TROUBLE DIAGNOSIS 8 Cooling Fan (Overheat) (Cont’d) COMPONENT INSPECTION Cooling fan relays-1, -2, -3

Cooling fan relay 1

Check continuity between terminals

3 p

and

5 . p

Conditions 5 1

2 3

Continuity

12V direct current supply between relay terminals p 1 and p 2

Yes

No current supply

No

If NG, replace cooling fan relay.

Cooling fan relay-2

Cooling fan relay 3

Check continuity between terminals

3 p

and

Conditions

2

5 4

1

3

4 . p

Continuity

No current supply

Yes

12V direct current supply between relay terminals p 1 and p 2

No

Cooling fan relay 2

2

5 4

1

3

YEC391

Cooling fan motors-1 and -2 1. Disconnect cooling fan motor harness connectors. 2. Supply cooling fan motor terminals with battery voltage and check operation.

Cooling fan motor-1 & -2

Terminals FUSE

Cooling fan motor-1 and -2 AEC781

Cooling fan motor should operate. If NG, replace cooling fan motor.

EC-96

(!)

(@)

1 p

2 p

CD20T

TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) Nozzle holder

Inductive pick-up coli

The needle lift sensor is built into the No. 1 nozzle. Its inductive pick-up element senses the lifting of the injection nozzle needle and thus the start of injection. The signal is evaluated by the ECM and compared with the target timing. Deviations in timing, for example caused by changes in fuel temperature, are sensed by the ECM and corrected.

Nozzle NEF689

Check Items (Possible Cause)

Malfunction is detected when .... ●

An improper signal from the sensor is sent to ECM.

●

● ● ●

Harness or connectors (The sensor circuit is open or shorted.) Needle lift sensor Air in fuel line Clogging No. 1 injection nozzle

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE NOTE: Before diagnostic trouble confirmation, be sure to check battery voltage is above 9V. 1) Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for 2 seconds above 1,200 rpm.

EC-97

TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) (Cont’d)

CD20T

NEEDLE LIFT SENSOR

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC806

EC-98

TROUBLE DIAGNOSIS 9 Needle Lift Sensor (NLS) (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE Priming pump

INSPECTION START

H

SEF671S

Needle lift sensor harness connector

CHECK FOR AIR IN FUEL FILTER. 1. Move priming pump up and down to purge air from fuel filter. 2. Perform “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE”.

H

SEF606S

CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and needle lift sensor harness connector. 3. Check harness continuity between needle lift sensor connector terminal 1 and ECM connector terminal p 345 . Continuity should exist. If OK, check harness for short-circuit.

Needle lift sensor connector

CHECK GROUND CIRCUIT. Check resistance between needle lift sensor connector terminal p 2 and ECM connector terminal 333 . Continuity should exist. If OK, check harness for short-circuit. H

Needle lift sensor connector

E

Repair harness or connectors.

E

Repair harness or connectors.

OK H

NEF206A

NG

OK

CHECK NO. 1 INJECTION NOZZLE FOR CLOGGING. Refer to spray pattern test of “INJECTION NOZZLE”. If NG, replace No. 1 injection nozzle. H

Disconnect and reconnect harness connectors in the circuit. Then retest. NEF205A H

Trouble is not fixed

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-99

NG

CD20T

TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve Fuel cut solenoid valve

ECM

Ignition switch

When the ignition switch is OFF, the ECM turns the fuel cut solenoid valve OFF (under this condition, no current flows through the fuel cut solenoid valve), shutting off fuel supply. When the engine is not operating due to trouble, the fuel cut solenoid valve may be OFF even when the ignition switch is ON.

SEF667S

Check Items (Possible Cause)

Malfunction is detected when ... ●

Fuel cut solenoid valve circuit is malfunctioning.

●

●

Harness or connectors (The solenoid valve circuit is open or shorted.) Fuel cut solenoid valve

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3) 4) 5) 6)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine. (If no start, circuit is open). Warm engine up sufficiently. Turn ignition switch to “LOCK” position and wait at least 5 seconds. Start engine and rev it up above 1,300 rpm. Release pedal and wait at least 3 seconds.

EC-100

TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d)

CD20T

BATTERY Refer to EL-POWER. : Detectable line for DTC : Non-detectable line for DTC

INJECTION PUMP (FUEL CUT SOLENOID VALVE)

ENGINE CONTROL MODULE RELAY

ECM

YEC807

EC-101

TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d) .

CD20T

DIAGNOSTIC PROCEDURE

Electronic injection pump harness connector (Fuel cut solenoid valve)

INSPECTION START H

CHECK MAIN POWER SUPPLY. Check power supply. Refer to EC-CD-59.

NEF815

C2FCS01

Electronic injection pump harness connection

NEF226A

H

NG CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “ON” position. 2. Select “FUEL CUT SOL/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON” and “OFF” alternately. 4. Check that operating sound is emitted. ----------------------------------------------------------------- OR ----------------------------------------------------------------1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector and electronic injection pump harness connector. 3. Check harness continuity between fuel cut solenoid valve connector terminal p 1 and ECM connector terminal 349 . Continuity should exist. If OK, check harness for short.

E

Repair harness or connectors.

E

Replace fuel cut solenoid valve.

OK H

CHECK COMPONENT (Fuel cut solenoid valve). Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed.

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-102

NG

TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve (Cont’d)

CD20T

COMPONENT INSPECTION FUSE

Shaft

Fuel cut solenoid valve 1. Remove fuel cut solenoid valve. 2. Check for lifting shaft when applying 12V direct current to terminals. If NG, replace fuel cut solenoid valve.

SEF859S

EC-103

CD20T

TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS)

The fuel temperature sensor is used to detect the fuel temperature in the injection pump. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the fuel temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. The sensor is built into the inside electrical circuit of the injection pump.

Check Items (Possible Cause)

Malfunction is detected when ... ●

An excessively high or low voltage from the sensor is detected by ECM.

●

●

Harness or connectors (The sensor circuit is open or shorted.) Fuel temperature sensor

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.

EC-104

CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d)

INJECTION PUMP (FUEL TEMPERATURE SENSOR)

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC808

EC-105

CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d) .

DIAGNOSTIC PROCEDURE

Electronic injection pump harness connector (Fuel temperature sensor)

INSPECTION START

H

NEF818

Injection pump connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect fuel temperature sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between injection pump connector terminal p 6 and ground with CONSULT-II or voltage tester. Voltage: Approximately 5V

NG

E

Repair harness or connectors.

E

Repair harness or connectors.

OK H

NEF819

Injection pump connector

F50

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between injection pump connector terminal 5 and ECM connector terminals p 335 , 436 . Continuity should exist. If OK, check harness for short-circuit.

NG

OK H NEF208A

CHECK COMPONENT (Fuel temperature sensor). Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuits. Then retest. Trouble is not fixed. H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest.

H

INSPECTION END

EC-106

NG

E

Have the injection pump assembly serviced by an authorised service representative.

CD20T TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor (FTS) (Cont’d)

COMPONENT INSPECTION Fuel temperature sensor Wait until fuel temperature sensor reaches room temperature. Check resistance between terminals p 5 and p 6 .

YEC366

Fuel temperature °C (°F)

Resistance kΩ

25 (77)

Approximately 1.9

If NG, have the injection pump assembly serviced by an authorised service representative.

EC-107

CD20T

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch

Output voltage between terminal No. 4 and 5 (V)

The accelerator position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. The ECM uses the signal to determine the amount of fuel to be injected.

Throttle valve opening angle (deg) NEF822

Check Items (Possible Cause)

Malfunction is detected when ... ●

An excessively low or high voltage from the sensor is detected by the ECM.

●

● ●

Harness or connectors (The sensor or switch circuit is open or shorted.) Accelerator position sensor Accelerator position switch

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Depress accelerator pedal fully and keep it for at least 1 second. Then release it and wait at least 5 seconds.

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE (For accelerator stiching) 1) 2) 3) 4)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Start engine and rev it up above 1,300 rpm. Depress brake pedal immediately after releasing accelerator pedal and keep it at least 5 seconds.

EC-108

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)

CD20T

ACCELERATOR POSITION SENSOR

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC809

EC-109

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)

CD20T

ECM

: Detectable line for DTC : Non-detectable line for DTC

DEPRESSED

ACCELERATOR WORK UNIT

RELEASED

YEC810

EC-110

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE Accelerator pedal

Accelerator position sensor harness connector

INSPECTION START (Accelerator position sensor)

H

NEF823

Accelerator position sensor connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect accelerator position sensor harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between accelerator position sensor connector terminal p 5 and ground with CONSULT-II or voltage tester. Voltage: Approximately 5V

NG E

Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor. If NG, repair harness or connectors.

OK H

NEF824

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between accelerator position sensor connector terminal 4 and engine ground. p Continuity should exist. If OK, check harness for short-circuit.

E

OK

Accelerator position sensor connector H

NEF825

NG

CHECK INPUT SIGNAL CIRCUIT. 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 434 and accelerator position sensor connector terminal p 2 . Continuity should exist. If OK, check harness for short-circuit.

NG E

OK H

Accelerator position sensor connector

CHECK COMPONENT (Accelerator position sensor). Refer to “COMPONENT INSPECTION” EC-CD-113. OK H NEF209A

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed. H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-111

NG E

Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor. If NG, repair harness or connectors.

Check the following ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and accelerator position sensor If NG, repair harness or connectors.

Replace accelerator pedal assembly.

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE INSPECTION START (Accelerator position switch)

H

PEF123W

NEF210A

CHECK OVERALL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Check “OFF ACCEL POS” in “DATA MONITOR” mode with CONSULT-II. Accelerator pedal released: ON Accelerator pedal depressed: OFF ---------------------------------------------------------------- OR ---------------------------------------------------------------1. Turn ignition switch to “LOCK” position. 2. Check continuity between ECM connector terminal 435 and ground. Continuity: Accelerator pedal released: No Accelerator pedal depressed: Yes

OK E

INSPECTION END

E

Check the following: ● Harness connectors M52 , F103 ● Harness for open circuit between accelerator switch and ECM connector terminal 426 . If NG, repair harness or connectors.

E

Check the following: ● Harness connectors F103 , M52 ● Harness for open or shortcircuit between accelerator switch and ECM

E

Replace accelerator switch.

NG H Accelerator switch connector

CHECK GROUND CIRCUIT. 1. Disconnect accelerator switch harness connector. 2. Check harness continuity between accelerator switch connector terminal 1 and ECM connector terminal 426 . p Continuity should exist.

NG

OK NEF212A

Accelerator switch connector

H

CHECK INPUT SIGNAL CIRCUIT. Check harness continuity between ECM connector terminal 435 and accelerator switch connector terminal p 3 . Continuity should exist. H

OK

CHECK COMPONENT (Accelerator switch). Refer to “COMPONENT INSPECTION” on next page. H NEF211A

OK

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-112

NG

NG

TROUBLE DIAGNOSIS 12 Accelerator Position Sensor & Switch (Cont’d)

Accelerator position sensor connector

CD20T

COMPONENT INSPECTION M68

1 2 3 4 5 2

Accelerator position sensor

M68

4

1. Disconnect accelerator position sensor harness connector. 2. Make sure that resistance between accelerator position sensor terminals p 2 and p 4 changes when opening throttle valve manually. Throttle valve conditions

YEC368

Completely closed

Resistance [at 25°C (77°F)] Approximately 1.2 kΩ

Partially open

1.2 - 1.9 kΩ

Completely open

Approximately 1.9 kΩ

If NG, replace accelerator pedal assembly. CAUTION: ● Do not disassemble accelerator pedal assembly.

COMPONENT INSPECTION

Accelerator position sensor connector

Accelerator switch M68

1 2 3 4 5 1

M68

3

1. Disconnect accelerator switch harness connector. 2. Check continuity between accelerator switch connector terminals p 1 and p 3 . Conditions

YEC369

Continuity

Accelerator pedal released

No

Accelerator pedal depressed

Yes

If NG, replace accelerator pedal assembly. CAUTION: ● Do not disassemble accelerator pedal assembly.

EC-113

CD20E

TROUBLE DIAGNOSIS 13 Core

Crankshaft Position Sensor (TDC) The crankshaft position sensor (TDC) monitors engine speed by means of signals from the sensing plate (with two protrusions) installed to the crankshaft pulley. The datum signal output is detected at ATDC 70° and sent to the ECM. The sensor signal is used for fuel injection control and fuel injection timing control.

Magnet Coil SEF615S

Crank pulley

Crankshaft position sensor (TDC)

SEF616S

Check Items (Possible Cause)

Malfunction is detected when .... ●

An incorrect signal from the sensor is detected by ECM during engine running and cranking.

●

●

Harness or connectors (The sensor circuit is open.) Crankshaft position sensor (TDC)

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Before performing the following procedure, confirm that battery voltage is more than 9V. 1) 2)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 3 seconds above 1,200 rpm.

EC-114

CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)

CRANKSHAFT POSITION SENSOR (TDC)

: Detectable line for DTC : Non-detectable line for DTC

ECM

YEC811

EC-115

CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)

DIAGNOSTIC PROCEDURE INSPECTION START

H

Crankshaft position sensor (TDC) harness connector

SEF617S

Crankshaft position harness connector

CHECK INPUT SIGNAL CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect crankshaft position sensor (TDC) and ECM harness connectors. 3. Check continuity between ECM terminal 344 and crankshaft position sensor (TDC) connector terminal 3 . p Continuity should exist. If OK, check harness for short-circuit.

NG

E

Repair harness or connectors.

E

Repair harness or connectors.

E

Replace crankshaft position sensor (TDC).

OK H NEF213A

Loosen and retighten engine ground screws. OK H

Crankshaft position sensor connector

CHECK GROUND CIRCUIT. Check harness continuity between crankshaft position sensor (TDC) connector terminal p 2 and ECM connector terminal 331 . Continuity should exist. If OK, check harness for short-circuit.

NEF214A

NG

OK H

CHECK COMPONENT [Crankshaft position sensor (TDC)]. Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-116

NG

CD20E TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor (TDC) (Cont’d)

COMPONENT INSPECTION Crankshaft position sensor (TDC)

SEF620S

Crankshaft position sensor (TDC) connector

1. Disconnect crankshaft position sensor (TDC) harness connector. 2. Loosen the fixing bolt of the sensor. 3. Remove the sensor. 4. Visually check the sensor for chipping. 5. Check resistance between crankshaft position sensor (TDC) terminals p 2 and p 3 . Resistance: Approximately 1.2 - 1.5kΩ [at 25°C (77°F)] If NG, replace crankshaft position sensor (TDC).

NEF440

EC-117

CD20T

TROUBLE DIAGNOSES 14 Glow Control System

.

Time , [S]

Glow lamp indicator

.

.

(-40) (-4) (32) (68) Engine coolant temperature

(104)

1.5

When coolant temperature is lower than 75°C (167°F): ● Ignition switch ON After ignition switch has been turned to ON, the glow relay turns ON for a period of time depending on engine coolant temperature, allowing current to flow through the glow plugs. ● Starting After starting the engine, current will flow through the glow plugs for 300 seconds, or until the coolant temperature exceeds 50°C (122°F).

(140)

, °C (°F)

.

Time , [S]

Pre-glow

.

(-40)

(-4)

(32)

(68)

(104) .

Engine coolant temperature

(140)

, °C (°F)

.

.

Time , [S]

Post glow

.

(-40) (-4) (32) (68). (104) (140) . Engine coolant temperature , °C (°F) NEF834

COMPONENT DESCRIPTION Glow plug Ceramic heater

Resistor

The glow plug is provided with a ceramic heating element to obtain a high-temperature resistance. It glows in response to a signal sent from the ECM, allowing current to flow through the glow plug via the glow relay.

SEF857S

Check Items (Possible cause)

Malfunction is detected when .... ●

Glow relay signal circuit is open or shorted.

●

● ●

Glow indicator lamp circuit is open or shorted.

●

●

Harness or connectors (The glow relay signal circuit is open or shorted) Glow relay Harness or connectors (The glow indicator lamp circuit is open or shorted.) Glow lamp

EC-118

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds.

EC-119

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

YEC102A

EC-120

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE Glow relay

INSPECTION START (Glow relay signal circuit) H

CHECK MAIN POWER SUPPLY. Check power supply to ECCS-D relay. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY” (EC-CD-59).

Glow relay harness connector NEF835

H

CHECK POWER SUPPLY. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect glow relay. 3. Turn ignition switch to the “ON” position. 4. Check voltage between glow relay connector terminals p 1 , p 5 and ground with tester. Voltage: Battery voltage

Glow relay connector

YEC370

NEF215A

E

Check the following: ● 15A fuse ● 80A fusible link ● Harness continuity between glow relay and fuse. If NG, replace fuse or fusible link or repair harness or connectors.

OK H

Glow relay connector

NG

CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM connector terminal 214 and 2 . glow relay connector terminal p Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check harness connectors F96 , E89 Repair harness or connectors.

OK H

CHECK GLOW PLUG AND GLOW RELAY. Refer to “COMPONENT INSPECTION” (EC-CD-124, 125). OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-121

NG

E

Replace glow plug or glow relay.

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

INSPECTION START (Glow indicator lamp circuit)

H

CHECK POWER SUPPLY CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between combination meter harness connector terminal 5 or p 1 and body ground. p Voltage: Battery voltage

NG

E

Check the following: ● Harness for open or short-circuit between combination meter and battery. ● 10A fuse If NG, replace fuse or repair harness or connectors.

OK H

YEC119A

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM connector terminal 221 and combination meter connector terminal p 7 or p 17 . Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check the following: ● Harness connectors M50 , F104 ● Harness for open or short-circuit between ECM and combination meter. If NG, repair harness or connectors.

OK H

CHECK GLOW INDICATOR LAMP. Make sure that glow indicator lamp is not burnt out. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H YEC120A

INSPECTION END

EC-122

NG

E

Replace glow indicator lamp.

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

INSPECTION START (Glow plug circuit) Glow relay connector H

NEF873

Glow relay connector

CHECK POWER SUPPLY-I. 1. Turn ignition switch to “LOCK” position. 2. Disconnect glow relay harness connector. 3. Check voltage between glow relay harness connector terminal p 5 and engine ground. Voltage: Battery voltage

NG

E

Check the following: ● Harness for open or short-circuit between glow relay and battery. ● 80A fusible link If NG, replace fusible link and repair harness connectors.

OK

Glow plug connector H

YEC374

CHECK POWER SUPPLY-II. 1. Disconnect glow plug harness connector. 2. Check harness continuity between glow plug harness connector and glow relay harness connector terminal p 3 . Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check the following: ● Harness connectors E2 , F46 ● Harness for open or short-circuit between glow plug and glow relay. If NG, repair harness or connector.

OK H

CHECK GLOW PLUG AND GLOW RELAY. Refer to “COMPONENT INSPECTION” (EC-CD-124, 125). OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. H

INSPECTION END

EC-123

NG

E

Replace glow plug or glow relay.

CD20T

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d) SYSTEM OPERATION CHECK Set voltmeter between glow plug and engine body.

Glow plug plate

SEC554B

Pre-glow time

1. Pre-glow control system a. Turn ignition switch to “ON” position. b. Read voltage. Voltage: Battery voltage for an engine coolant temperature dependent time. * Repeatedly turning the ignition switch to “ON” position and to “LOCK” position may change the pre-glow time. .

(-4) (32) (68) (104) Engine coolant temperature

NEF838

After glow time (sec.)

2. After-glow system Start engine and read voltage. Voltage: Battery voltage for 5* minutes * Engine coolant temperature is lower than 50°C (122°F).

.

(-4)

(32)

(68)

Engine coolant temperature

(104) NEF839

COMPONENT INSPECTION Glow relay

Glow relay

p

p

p5

p1

3

1. Check relay for coil continuity between glow relay terminals 1 and p 2 . p Continuity should exist. 2. Check relay for proper operation by applying 12V dc voltage between glow relay terminals p 1 and p 2 and checking continuity between terminals p 3 and p 5 .

2

Coil voltage Contact point

Continuity

3 p

and

5 p

Contact point

0V

No

OFF

12V

Yes

ON

12V dc

Ohmmeter SEC564B

EC-124

TROUBLE DIAGNOSES 14 Glow Control System (Cont’d)

CD20T

Glow plug

Ohmmeter

1. Remove glow plug connecting plate. 2. Check each glow plug for continuity. Continuity should exist: Approximately 0.5Ω [at 25°C (77°F)] ● If NG, replace glow plug.

SEF630K Glow nut

Glow harness

Connecting plate Washer Spring washer Glow plug

3. Install glow plug connecting plate securely. ● Do not bump glow plug heating element. If it is bumped, replace glow plug with new one. (If glow plug is dropped from a height of 0.1 m (3.94 in) or greater, replace with new one.) ● If glow plug installation hole is contaminated with carbon, remove using a reamer or suitable tool. ● Hand-tighten glow plug by turning it 2 to 3 times, then tighten using a tool to specified torque. : 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)

SEC565B

EC-125

CD20T

TROUBLE DIAGNOSES 15 Air Conditioner Cut Control

The Air Conditioner relay is controlled by the ECM. During the following conditions, the ECM will cut the power supply towards the air conditioner relay: ● Starting engine ● Quick acceleration from low speed ● Undershooting of idle speed ● High engine coolant temperature [above 107°C (225°F)]. ● Malfunctioning of engine speed sensor, accelerator position sensor or vehicle speed sensor when engine speed is below 2,100 rpm.

Check Items (Possible cause)

Malfunction is detected when .... ●

Air conditioner relay signal circuit is shorted.

●

●

Harness or connectors (The air conditioner relay signal circuit is shorted). Air conditioner relay

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch and air conditioner switch to the “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.

EC-126

CD20T

TROUBLE DIAGNOSES 15 Air Conditioner Cut Control (Cont’d) IGNITION SWITCH ON or START FUSE BLOCK (J/B)

Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC

AIR CONDITIONER RELAY

To compressor (Refer to HA-A/C.) A/C CONTROL PANEL

LOW

HIGH

THERMO CONTROL AMP.

TRIPLEPRESSURE SWITCH

NORMAL THERMISTOR

ECM

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEC813

EC-127

TROUBLE DIAGNOSES 15 Air Conditioner Cut Control (Cont’d)

CD20T

INSPECTION START (Air conditioner relay signal circuit) Air conditioner relay harness connector H

YEC375

Air conditioner relay harness connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect air conditioner relay harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between air conditioner relay connector terminals p 2 , 5 and engine ground. p Voltage: Battery voltage

E

Check the following: ● Harness and connectors for open or shortcircuit between ignition switch and air conditioner relay. ● 10A fuse If NG, replace or repair the parts affected.

OK H

NEF218A

NG

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM harness connector terminal 204 and air conditioner relay harness connector terminal p 1 . Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check the following: ● Harness connectors E43 , F2 ● Harness for open or short-circuit between ECM and air conditioner relay. If NG, repair harness or connectors.

OK H

CHECK AIR CONDITIONER RELAY. Refer to HA section for inspection. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-128

NG

E

Replace air conditioner relay.

CD20T

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve SYSTEM DESCRIPTION Camshaft position sensor (TDC)

Air conditioner switch

Engine coolant temperature sensor

Atmospheric pressure sensor

Mass air flow sensor

Engine speed E

Air conditioner “ON” signal E

Engine coolant temperature E

E

EGRC-solenoid valve

ECM

Atmospheric pressure E

Mass air flow E

The ECM receives signals sent from the engine coolant temperature sensor, crankshaft position sensor (TDC), atmospheric pressure sensor, mass air flow sensor and air conditioner switch to determine engine speed and operating conditions. Based on these signals, the ECM controls the EGR control solenoid valve operation. No EGR operation will take place when the engine coolant temperature is below 70°C (158°F), when idling, at starting and during a period of time after starting the engine (70 - 200 seconds, depending on engine coolant temperature). Engine coolant temperature °C (°F) Below 70 (158)

Load

EGRC-solenoid valve

EGR valve

Amount of EGR gas

Any

OFF (Closed)

Fully closed

—

Low load

ON (Open)

Fully open

Large

High load

OFF (Closed)

Fully closed

—

Above 70 (158)

COMPONENT DESCRIPTION

To control valve To intake air flow

Vacuum signal

The EGR control solenoid valves control vacuum pressure acting on the EGR valve. The EGR control valve will then be fully opened or fully closed, as required. Thus, intake air passages are opened or closed in relation to exhaust gas and intake air. Utilizing the relationship between exhaust gas pressure and intake air pressure control, the amount of EGR (exhaust gas recirculated) is regulated in large or small volumes.

SEF240PH

Check Items (Possible cause)

Malfunction is detected when .... ●

EGRC-solenoid valve A circuit is shorted.

●

●

Harness or connectors (EGRC-solenoid valve A circuit is open or shorted). EGRC solenoid valve A

EC-129

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)

CD20T

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to the “ON” position. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 2 seconds.

EC-130

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)

CD20T

BATTERY : Detectable line for DTC

Refer to EL-POWER.

: Non-detectable line for DTC

ENGINE CONTROL MODULE RELAY EGRCSOLENOID VALVE A

EGRCSOLENOID VALVE B

ECM

YEC814

EC-131

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE INSPECTION START (Circuit for EGRC-solenoid valve A)

EGRC solenoid valve A harness connector

H

CHECK MAIN POWER SUPPLY. Refer to Trouble Diagnosis for main power supply (EC-CD-59) NEF219A

EGRC solenoid valve A harness connector

H

CHECK POWER SUPPLY. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect EGRC-solenoid valve A harness connector. 3. Turn ignition switch to the “ON” position. 4. Check voltage between connector terminal p 2 and engine ground. Voltage: Battery voltage

NG

E

Check the following: ● Harness continuity between ECM relay and EGRC-solenoid valve A connector. If NG, repair harness or connectors.

OK

NEF220A H

CHECK OUTPUT SIGNAL CIRCUIT. 1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM harness connector terminal 208 and EGRC solenoid valve A 1 . connector terminal p Continuity should exist. If OK, check harness for short-circuit.

NG

E

Check the following: ● Harness for open or short-circuit between ECM and solenoid valve. If NG, repair harness or connectors.

OK H

CHECK COMPONENTS (EGRC-solenoid valve). Refer to “COMPONENT INSPECTION” EC-CD-135. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage or the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-132

NG

E

Replace malfunctioning component(s).

CD20T

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START EGR CONTROL OPERATION

EGR valve

H

NEF433

EGR valve

NEF434

OK CHECK OVERALL FUNCTION. 1. Start engine and warm it up sufficiently. (Air conditioner is “OFF”). 2. Perform diagnostic test mode II (Self-diagnostic results). Make sure that diagnostic trouble code No. 55 is displayed. 3. Make sure that EGR diaphragm moves up and down (Use your finger or a suitable tool) under the following conditions: At idle: Spring does not move. Racing engine from idle to 2800 rpm: Spring moves up and down.

E

INSPECTION END

NG H

CHECK VACUUM SOURCES TO EGR VALVE. 1. Disconnect vacuum hoses to EGR valve. 2. Make sure that vacuum exists under the following conditions: At idle: Vacuum should not exist. Racing engine from idle to 2800 rpm: Vacuum should exist. H

A p

EC-133

NG

OK

E

CHECK COMPONENTS (EGR valve). (See page EC-CD-135.) NG

H

Replace malfunctioning component(s).

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d)

CD20T

A p

H

C2ESA01

OK CHECK CONTROL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Turn EGRC-solenoid valve A “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound. -------------------------------------------------------------------- OR -------------------------------------------------------------------1. Check voltage between EGRC solenoid valve A connector terminal p 1 , and ground with tester under the following conditions: Voltage: At idle Battery voltage Engine speed is 2,800 rpm Approximately 0.4V

NEF435

NG H

Perform electrical circuit inspection. Refer to EC-CD-132.

Crack

H

B p

Clogging

Improper connection NEF846 . .

EGRC-solenoid valve harness connector

NEF436

EC-134

OK

E

CHECK VACUUM HOSE. Check vacuum hose for clogging, cracks or improper connection.

CD20T

TROUBLE DIAGNOSES 16 EGRC-Solenoid Valve (Cont’d) COMPONENT INSPECTION EGR valve

EGR valve Apply vacuum to EGR vacuum port with a hand vacuum pump. EGR valve spring should lift. If NG, replace EGR valve.

MEF137D

EGRC-solenoid valve Check air passage continuity.

FUSE

Condition

BATTERY

Air passage continuity between p A and

B p

Air passage continuity between p A and

12V direct current supply between terminals 1 and p 2 p

Yes

No

No supply

No

Yes

MEC488B

If NG, replace solenoid valve.

EC-135

C p

CD20T

TROUBLE DIAGNOSES 17 Brake Switch

The ECM receives signals from two brake switches. One is a conventional brake lamp switch, the other is referred to as a redundant (RDNT) brake switch. In case the accelerator pedal does not return to the idle position (pedal sticks), the driver will react by depressing the brake. In this (emergency) situation, the ECM will disregard the accelerator pedal signal and bring back the engine speed to 1200 rpm. Check Items (Possible Cause)

Malfunction is detected when ... ●

Brake switch circuits are open or shorted.

●

● ●

Harness or connectors (Brake switch circuits are open or shorted.) Stop lamp switch RDNT brake switch

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. Depress brake pedal for at least 1 minute.

EC-136

TROUBLE DIAGNOSES 17 Brake Switch (Cont’d)

CD20T

YEC103A

EC-137

CD20T

TROUBLE DIAGNOSES 17 Brake Switch (Cont’d) INSPECTION START (RDNT brake switch) RDNT brake switch harness connector

H

YEC377

RDNT brake switch harness connector

CHECK POWER SUPPLY. 1. Turn ignition switch to “LOCK” position. 2. Disconnect RDNT brake switch harness connector. 3. Turn ignition switch to “ON” position. 4. Check voltage between RDNT brake switch harness connector terminal 1 and body ground. p Voltage: Battery voltage

NG

E

OK

Check the following: ● Harness connectors F104 , M50 (RHD models) ● Harness connectors F2 , E43 (LHD models) ● Harness for open or short-circuit between RDNT brake switch harness connector terminal p 1 and ECM connector terminal 416 . If NG, repair harness or connectors.

YEC378 H

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Check harness continuity between RDNT brake switch harness connector terminal p 2 and body ground. Continuity should exist. If OK, check harness for shortcircuit. OK H

CHECK COMPONENT. (RDNT brake switch) Refer to “COMPONENT INSPECTION” on next page. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-138

NG

E

Repair harness or connectors.

CD20T

TROUBLE DIAGNOSES 17 Brake Switch (Cont’d) COMPONENT INSPECTION

2 1

Stop lamp switch and RDNT brake switch 1 2

YEC379

1. Turn ignition switch to “LOCK” position. 2. Disconnect switch harness connectors. 3. Check continuity between terminals p 1 and Continuity:

2 . p

Brake pedal

Stop lamp switch

RDNT brake switch

Released

No

No

Depressed

Yes

Yes

If NG, replace stop lamp switch or RDNT brake switch.

EC-139

CD20T

TROUBLE DIAGNOSES 18 ECM Relay

The ECM Relay shuts off the main power supply to the ECM within 5 seconds after the ignition switch has turned to the “LOCK” position.

Check Items (Possible cause)

Malfunction is detected when .... ●

ECM relay shut-off time is too late.

●

● ●

Harness or connectors (The ECM relay circuit is shorted). ECM relay ECM

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1) 2) 3)

Turn ignition switch to the “ON” position and select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch to the “LOCK” position and wait at least 5 seconds. Turn ignition switch to the “ON” position and wait at least 2 seconds.

DIAGNOSTIC PROCEDURE Refer to “Trouble Diagnosis for Power Supply” (EC-CD-59) for ECM relay circuit inspection.

EC-140

CD20T

TROUBLE DIAGNOSES 19 MI & Data Link Connectors

Malfunction indicator (MI) circuit is monitored for open or shortcircuit. If the circuit is malfunctioning, MI can not report it but CONSULT-II can. Check Items (Possible cause)

Malfunction is detected when .... ●

MI circuit is open or shorted.

●

● ●

Harness or connectors (MI circuit is open or shorted). MI lamp ECM

DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1)

Turn ignition switch to “ON” position and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and run it for at least 2 seconds at idle speed. ------------------------------------------------------------------------------------------------------------------------------- OR ------------------------------------------------------------------------------------------------------------------------------OVERALL FUNCTION CHECK 1) Turn ignition switch to “ON” position. 2) Check that MI lits on.

EC-141

TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)

CD20T

YEC104A

EC-142

TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE: MODELS BEFORE VIN P11U0548750 INSPECTION START (MI circuit)

Combination meter harness connector

H

YEC380

Combination meter harness connector

CHECK MI BULB. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Apply battery voltage between combination meter terminal p 5 and p 13 . 4. Check that MI lits on.

NG

E

Replace MI bulb.

OK H

YEC381

CHECK POWER SUPPLY. 1. Turn ignition switch to “ON” position. 2. Check voltage between combination meter terminal p 5 and body ground. Voltage: Battery voltage

NG

E

OK Combination meter harness connector

NEF222A

Check the following: ● Harness for open or short-circuit between combination meter and ignition switch. ● 10A fuse If NG, repair or replace harness or fuse.

H

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check continuity between combination meter connector terminal p 13 and ECM connector terminal 215 . Continuity should exist. If OK, check harness for short-circuit. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-143

NG

E

Check the following: ● Harness connectors M50 , F104 If NG, repair harness or connectors. ● Harness and connectors for open or shortcircuit between ECM and combination meter.

TROUBLE DIAGNOSES 19 MI & Data Link Connectors (Cont’d)

CD20T

DIAGNOSTIC PROCEDURE: MODELS AFTER VIN P11U0548750 INSPECTION START (MI circuit)

H

YEC121A

CHECK MI DIODE. 1. Turn ignition switch to “LOCK” position. 2. Disconnect combination meter harness connector. 3. Apply battery voltage between combination meter terminal p 1 and p 8 . 4. Check that MI lits on.

NG

E

Repair or replace combination meter.

OK H

YEC122A

CHECK POWER SUPPLY. 1. Turn ignition switch to “ON” position. 2. Check voltage between combination meter terminal p 1 and body ground. Voltage: Battery voltage

NG

E

OK

Check the following: ● Harness for open or short-circuit between combination meter and ignition switch. ● 10A fuse If NG, repair or replace harness or fuse.

H

YEC123A

CHECK GROUND CIRCUIT. 1. Turn ignition switch to “LOCK” position. 2. Disconnect ECM harness connector. 3. Check continuity between combination meter connector terminal p 8 and ECM connector terminal 215 . Continuity should exist. If OK, check harness for short-circuit. OK H

Disconnect and reconnect harness connectors in the circuit. Then retest. Trouble is not fixed H

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-144

NG

E

Check the following: ● Harness connectors M50 , F104 If NG, repair harness or connectors. ● Harness and connectors for open or shortcircuit between ECM and combination meter.

CD20T

TROUBLE DIAGNOSES 20 Start Signal BATTERY

Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC

OFF

ST

ACC

IGNITION SWITCH

ON

FUSE BLOCK (J/B)

Refer to EL-POWER.

ECM

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEC817

EC-145

CD20T

TROUBLE DIAGNOSES 20 Start Signal (Cont’d) DIAGNOSTIC PROCEDURE INSPECTION START

H

C2DMM04

NEF223A

Fuse

CHECK OVERALL FUNCTION. 1. Turn ignition switch to “ON” position. 2. Check “START SIGNAL” in “DATA MONITOR” mode with CONSULT-II. IGN “ON”

OFF

IGN “START”

ON

OK

INSPECTION END

E

-------------------------------------------------------------------- OR -------------------------------------------------------------------1. Turn ignition switch to the “LOCK” position. 2. Disconnect ECM harness connector. 3. Turn ignition switch to “START” position. 4. Check voltage between ECM connector terminal 422 and ground. Voltage: Ignition switch “START” — Battery voltage Except above — Approximately 0V H

NG

Check if 10A fuse is OK.

NG

E

Replace 10A fuse.

OK NEF224A

H

CHECK INPUT SIGNAL CIRCUIT. 1) Turn ignition switch to “LOCK” position. 2) Disconnect 10A fuse. 3) Check harness continuity between ECM connector terminal 422 and fuse block. Continuity should exist. If OK, check harness for short-circuit. H

OK

Disconnect and reconnect harness connectors in the circuit. Then retest. H

Trouble is not fixed

Check ECM pin terminals for damage and check the connection of ECM harness connector. Reconnect ECM harness connector and retest. H

INSPECTION END

EC-146

NG

E

Check the following: Harness or connectors M50 , F104 ● Harness for open or short-circuit between ECM and fuse block. If NG, repair harness or connectors. ●

CD20T

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Unit : rpm Engine

Pump numbers

CD20T

Maximum engine speed

5,400

A/C ON

825 ± 25

A/C OFF

825 ± 25

Idle speed

Engine

Part number

Pump assembly number

CD20T

16700 2J620

NP-VE4/ 10E2200L736

Pump data is not yet available. Refer to CALIBRATION STANDARD published by BOSCH.)

Injection Nozzle INSPECTION AND ADJUSTMENT Injection nozzle assembly Unit: kPa (bar, kg/cm2, psi) Initial injection pressure New

14,423 - 15,651 (144.2 - 156.5, 148 - 159, 2,091 - 2,269)

Used

15,000 - 16,000 (150.0 - 160.0, 153 - 163, 2,175 - 2,320)

Inspection and Adjustment Plunger lift (Injection timing)

mm (in)

ELECTRIC GOVERNOR

0.89 ± 0.08 at plunger lift timing mark

Resistance [at 25°C (77°F)]

MASS AIR FLOW SENSOR

Ω

1.0

CRANKSHAFT POSITION SENSOR (TDC)

Supply voltage

V

5.0V

Output voltage

V

1.9 - 2.3*

Resistance [at 25°C (77°F)]

Ω

Approximately 1,215 - 1,485

Ω

0.5

*: Engine is warmed up sufficiently and idling under no-load.

GLOW PLUG ENGINE COOLANT TEMPERATURE SENSOR Temperature °C (°F)

Resistance kΩ

20 (68)

2.1 - 2.9

50 (122)

0.68 - 1.00

90 (194)

0.236 - 0.260

Resistance [at 25°C (77°F)]

ACCELERATOR POSITION SENSOR Throttle valve conditions Completely closed Partially open

CONTROL SLEEVE POSITION SENSOR Resistance [at 25°C (77°F)]

Ω

Completely open

Resistance kΩ [at 25°C (77°F)] Approximately 1.2 1.2 - 1.9 Approximately 1.9

6.0

FUEL TEMPERATURE SENSOR INJECTION TIMING CONTROL VALVE Resistance [at 25°C (77°F)]

Ω

Approximately 15

EC-147

Temperature °C (°F)

Resistance kΩ

25 (77)

Approximately 1.9

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

EC-148

CD20T

ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION

FE FE

CONTENTS PREPARATION.............................................................. 2 Special Service Tool .................................................. 2

QG16DE, QG18DE, SR20DE ACCELERATOR CONTROL SYSTEM ......................... 3 Adjusting Accelerator Cable ...................................... 4

CD20T ACCELERATOR CONTROL SYSTEM ......................... 5

QG16DE, QG18DE, SR20De, CD20T FUEL SYSTEM .............................................................. 6 Fuel Pump and Gauge .............................................. 7 EXHAUST SYSTEM ...................................................... 9

PREPARATION Special Service Tool Tool number Tool name

Description

KV999G0010 Fuel tank lock ring socket

Removing and installing fuel tank lock ring

NT057

FE-2

ACCELERATOR CONTROL SYSTEM

QG16DE, QG18DE, SR20DE

CAUTION: ● When removing accelerator cable, mark location to indicate lock nut’s initial position. ● Check that throttle valve is completely open when accelerator pedal is fully depressed. Check that throttle valve returns to idle position when accelerator pedal is released. ● Check accelerator control does not interfere with any adjacent parts. ● When connecting accelerator cable, be careful not to twist or scratch cable. SEC. 180

p1

p2

(LHD models)

p1

p2

(RHD models)

3 - 4 (0.3 - 0.4, 27 - 35) 3 - 4 (0.3 - 0.4, 27 - 35)

p3

3 - 4 (0.3 - 0.4, 27 - 35)

p4 p5

: N·m (kg-m, in-lb) NFE062 1 p 2 p

Accelerator cable Cable bracket

3 p 4 p

Pedal bracket Return spring

FE-3

5 p

Accelerator pedal

ACCELERATOR CONTROL SYSTEM

QG16DE, QG18DE, SR20DE

Adjusting Accelerator Cable Throttle drum

Lock nut 8 - 11 N·m (0.8 - 1.1 kg-m, 71 - 97 in-lb)

1. Loosen lock nut, and tighten adjusting nut until throttle drum starts to move. 2. From that position turn back adjusting nut 1.5 to 2 turns, and secure lock nut.

Accelerator Adjusting nut NFE020

FE-4

CD20T

ACCELERATOR CONTROL SYSTEM SEC. 180

6 - 7 (0.61 - 0.71, 53.1 - 62.0) 2.9 - 3.9 (0.3 - 0.4, 25.7 - 34.5)

p1

p2 p3 p5

2.9 - 3.9 (0.30 - 0.40, 25.7 - 34.5)

p4

: Apply grease : N·m (kg-m, in-lb) : Do not re-use NFE043 1 p 2 p

Pedal bracket Accelerator position sensor

3 p 4 p

Accelerator cable Return spring

●

5 p

Accelerator pedal

If MIL illuminates after engine has started, refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION” in EC section for instructions.

FE-5

FUEL SYSTEM WARNING: When replacing fuel line parts, be sure to observe the following: ● Display a “CAUTION: INFLAMMABLE” sign in workshop. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. ● Be sure to disconnect battery ground cable before conducting service operations. ● Be sure to furnish workshop with a CO2 fire extinguisher. ● Pour drained fuel into an explosion-proof container then ensure container lid is installed securely. CAUTION: ● For ECCS engine models, release fuel pressure from fuel line. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). ● Do not disconnect any fuel line unless absolutely necessary. ● Plug hose and pipe openings to prevent entry of dust or dirt. ● Always replace top lid seal and hose clamps with new ones. ● Do not kink or twist hoses and tubes during installation. ● Do not tighten hose clamps excessively because this could cause damage to the hose. ● Ensure fuel check valve is installed in the correct orientation. Refer to EC section (“FUEL CHECK VALVE”, “EVAPORATIVE EMISSION SYSTEM”). ● After installation, run engine and check for fuel leaks at connections. QG & SR engine models SEC. 172

CD engine models

p 1

p1

p4 p3 p2 p2

27 - 36 (2.8 - 3.9, 20 - 27)

7.9 - 10.4 (0.81 - 1.06, 69.9 - 92.1)

31 - 35 (3.2 - 3.6, 23 - 26)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NFE078

1 p 2 p

Top lid Fuel gauge

3 p 4 p

Fuel pump Fuel chamber

FE-6

FUEL SYSTEM Fuel Pump and Gauge REMOVAL 1. Release fuel pressure from fuel line. Refer to EC section (“Fuel Pressure Release”, “BASIC SERVICE PROCEDURE”). 2. Remove inspection hole cover located under the rear seat.

NFE023

3. Remove fuel filler lid. 4. Disconnect fuel outlet, return tube and connectors. CAUTION: Mark the fuel tubes to ensure correct position during installation.

Fuel tube

Connectors

SFE385A

5. Using SST KV999G0010, remove fuel gauge locking ring. 6. Lift the top plate from the fuel tank. CAUTION: ● Do not disconnect fuel hoses from top plate. Top plate has to be removed together with fuel chamber assy. ● For CD20T models the fuel gauge sender unit is attached to the top plate.

UFE004

.

.

Slide chamber

QG16DE, QG18DE & SR20DE models only: 7. Remove fuel pump with fuel tank chamber assy as follows: a. Push the locking clip upwards and slide the pump chamber assy towards the rear of the vehicle. b. Lift the pump chamber assy from the bracket. c. Carefully remove the pump chamber assy and top plate from the tank. CAUTION: While removing the pump chamber assy lift the fuel gauge sender float, to prevent it from bending.

PUSH Locking clip

NFE015

8. Take off the fuel pump chamber lid by opening out the 4 clips. Remove the fuel pump from the fuel pump chamber. 9. Remove the fuel gauge sender unit from the chamber by lifting the clip and sliding the sender unit upwards.

NFE016

FE-7

FUEL SYSTEM Fuel Pump and Gauge (Cont’d) INSTALLATION Installation is reverse procedure of removal. CAUTION: ● Always use a new top plate seal. ● Use the alignment marks to position the top plate. ● Tighten to specified torque.

FE-8

EXHAUST SYSTEM

SFE180A

CAUTION: ● Always replace exhaust gaskets with new ones when reassembling. Scrape off all residue of old gasket from flange surface. ● With engine running, check all tube connections for exhaust gas leaks, and entire system for unusual noises. ● After installation, check to ensure that mounting brackets and mounting insulators are free from undue stress. If any of the above parts are not installed properly, excessive noise or vibration may be transmitted to the vehicle body.

QG engine models SEC. 200⋅208

12.7 - 15.7 (1.30 - 1.60, 9.4 11.6)

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)

40 - 60 (4.1 - 6.1, 30 - 44)

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

Gasket Catalyst

36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3)

30 - 35 (3.1 - 3.5, 23 - 25) Gasket

51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)

Gasket Gasket

Without catalyst 5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use NFE079

FE-9

EXHAUST SYSTEM SR engine models SEC. 200⋅208

12.7 - 15.7 (1.30 - 1.60, 9.4 11.6)

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)

40 - 60 (4.1 - 6.1, 30 - 44)

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

Gasket Catalyst

36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3)

60 - 70 (6.1 - 7.1, 44 - 51) Gasket

51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)

Gasket Gasket

Without catalyst 5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.6)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use NFE080

FE-10

EXHAUST SYSTEM CD engine model SEC. 200⋅208

Gasket

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

51.0 - 64.7 (5.20 - 6.60, 37.6 - 47.7)

36.3 - 45.1 (3.7 - 4.6, 26.8 - 33.3) 12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

60.0 - 70.0 (6.12 - 7.14, 44.3 - 51.6) Gasket

Gasket

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Do not re-use

NFE077

FE-11

EXHAUST SYSTEM NOTE

FE-12

CLUTCH SECTION

CL

CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Preparation ................................................................ 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 CLUTCH SYSTEM......................................................... 4 INSPECTION AND ADJUSTMENT ............................... 5 Inspecting and Adjusting Clutch Pedal...................... 5 Bleeding Procedure ................................................... 7

HYDRAULIC CLUTCH CONTROL ............................... 8 Clutch Master Cylinder .............................................. 8 Clutch Operating Cylinder ......................................... 9 Clutch Damper......................................................... 10 CLUTCH RELEASE MECHANISM ..............................11 CLUTCH DISC AND CLUTCH COVER ...................... 13 Clutch Disc............................................................... 13 Clutch Cover and Flywheel ..................................... 14 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 15 General Specifications............................................. 15 Inspection and Adjustment ...................................... 16

CL

PRECAUTIONS AND PREPARATION Precautions ● ● ● ● ● ●

GG94310000

SBR820B

Recommended fluid is brake fluid “DOT 4”. Do not reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. When removing and installing clutch piping, use Tool. Use new brake fluid to clean or wash all parts of master cylinder, operating cylinder and clutch damper. Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system.

WARNING: After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

Preparation SPECIAL SERVICE TOOLS Tool number Tool name

Description

GG94310000 Flare nut torque wrench

Removing and installing clutch piping

a: 10 mm (0.39 in)

NT406

KV30101600 (New) KV30101000 (Former) Clutch aligning bar

Installing clutch cover and clutch disc

a: 15.9 mm (0.626 in) dia. b: 17.9 mm (0.705 in) dia. c: 40 mm (1.57 in)

NT645

ST20050240 Diaphragm spring adjusting wrench

Adjusting unevenness of diaphragm spring of clutch cover

a: 150 mm (5.91 in) b: 25 mm (0.98 in)

NT404

COMMERCIAL SERVICE TOOLS Tool name

Description

Equivalent to GG94310000 1 Flare nut crows foot p 2 p Torque wrench

Removing and installing clutch piping

a: 10 mm (0.39 in)

NT360

CL-2

2 1

ENGINE MOUNTING (Loose)

Refer to EM section

CLUTCH DISC (Out of true)

CL-13

CLUTCH DISC (Runout is excessive)

CL-13

5

CLUTCH DISC (Lining broken)

CL-13

5

CLUTCH DISC (Dirty or burned)

CL-13 CL-13 CL-13 CL-13

CLUTCH DISC (Lack of spline grease)

CL-13

DIAPHRAGM SPRING (Damaged)

CL-14

DIAPHRAGM SPRING ( Out of tip alignment)

CL-14

4

CLUTCH COVER (Distortion)

CL-14

5

1

CL-11

FLYWHEEL (Discoloration)

CL-14

5

RELEASE BEARING (Worn, dirty or damaged)

2

5 2

2

2

2

CLUTCH DISC (Worn out)

2

5

CLUTCH DISC (Oily)

CLUTCH DISC (Hardened)

5 3

6

2

6 7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

2

OPERATING CYLINDER PISTON CUP (Damaged)

NVH Troubleshooting Chart

1

CL-9

MASTER CYLINDER PISTON CUP (Damaged)

4

CL-8

CLUTCH LINE (Air in line)

3

CL-7

2

CL-5

Use the chart below to help you to find the cause of the symptom. The numbers indicate the order of inspection. Check each part in order. If necessary, repair or replace these parts.

Reference page

Clutch grabs/chatters

Clutch pedal spongy

1

Clutch noisy

Clutch slips

1

SUSPECTED PARTS (Possible cause)

Symptom

Clutch does not disengage

CL-3

CLUTCH PEDAL (Free play out of adjustment)

CLUTCH SYSTEM

YCL007

CL-4

INSPECTION AND ADJUSTMENT Inspecting and Adjusting Clutch Pedal Inspect and adjust clutch pedal stroke. Pedal stroke “S”: Refer to SDS, CL-16.

Pedal bracket

Pedal stopper bolt

Pedal pad

NCL057

B Pedal fully depressed position Master cylinder push rod Pedal bracket

A Pedal fully up position Pedal stopper bolt

NCL058

CL-5

INSPECTION AND ADJUSTMENT Inspecting and Adjusting Clutch Pedal (Cont’d) INSPECITON Pedal stroke Check clutch pedal stroke using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the middle of the clutch pedal pad. Place a book/clipboard on the driver’s set to set a reference point, ensure the book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule. Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard. Measure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified pedal stroke in the table, adjust actual pedal stroke if necessary (refer to “ADJUSTMENT”). Note: ● Do not use steering wheel as a reference point, angle gives incorrect reading. ● Ensure there is no interference between the floor carpet and clutch pedal when fully depressed.

SCL702

Pedal free play Check pedal free play. If out of specification, refer to “ADJUSTMENT”. ● Push on the clutch pedal until resistance is felt, and check the distance the pedal moves.

ADJUSTMENT Pedal stroke 1. 2. 3. 4.

Loosen the pedal stopper bolt completely (so there is no contact between pedal and stopper bolt). Adjust pedal stroke to the specified value with the master cylinder push rod. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut. Once stroke is set to specification, adjust clutch pedal free play.

Pedal free play 1. Adjust pedal free play to the specified value with the master cylinder push rod. 2. Tighten lock nut of the master cylinder push rod. ● Push on the clutch pedal until resistance is felt, and check the distance the pedal moves. Pedal free play “A”: Refer to SDS, CL-16.

CL-6

INSPECTION AND ADJUSTMENT Bleeding Procedure .

.

Operating cylinder

Air bleeder valve .

NCL005 Air bleed valve

.

Clutch damper

1. Bleed air from clutch operating cylinder according to the following procedure. Carefully monitor fluid level at master cylinder during bleeding operation. a. Top up reservoir with recommended brake fluid. b. Connect a transparent vinyl tube to air bleeder valve of clutch operating cylinder. c. Fully depress clutch pedal several times. d. With clutch pedal depressed, open bleeder valve to release air. e. Close bleeder valve. f. Repeat steps (c) through (e) above until brake fluid flows from air bleeder valve without air bubbles. 2. Bleed air from clutch damper according to the above procedure. 3. Repeat the above bleeding procedures 1 and 2 several times.

NCL006

CL-7

HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder

YCL008

DISASSEMBLY AND ASSEMBLY ● ●

Push piston into cylinder body with screwdriver when removing and installing valve stopper. Check direction of piston cups.

INSPECTION ● ● ● ● ●

Check cylinder and piston contact surfaces for uneven wear, rust or damage. Replace if necessary. Check piston and piston cup for wear or damage. Replace if necessary. Check return spring for wear or damage. Replace if necessary. Check reservoir for deformation or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.

CL-8

HYDRAULIC CLUTCH CONTROL Clutch Operating Cylinder SEC. 306

Hydraulic pipe

18 - 25 (1.9 - 2.5, 14 - 18)

30 - 38 (3.1 - 3.8, 23 - 28) Operating cylinder

R p

Air bleeder valve 7 - 9 (0.8 - 0.9, 62 - 79)

Spacer Dust cover Push rod

Spring Piston assembly Piston cup

R p

R p

: Apply rubber grease

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NCL008

INSPECTION ● ● ● ●

Check contact surfaces of cylinder for wear, rust or damage. Replace if necessary. Check piston and piston cup for wear or damage. Replace if necessary Check piston spring for wear or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.

CL-9

HYDRAULIC CLUTCH CONTROL Clutch Damper SEC. 306

Cylinder body Bleeder Screw 6 - 10 (0.7 - 1.0, 54 - 88)

R Rubbing surp face to piston assembly

Gasket Spring

Piston cup

R p

Damper cover (LHD model)

Piston assembly Plate R p

2.9 - 5.9 (0.29 - 0.60, 26 - 52)

Contact surface to piston assembly Damper rubber

5.1 - 6.5 (0.52 - 0.66, 46 - 57) : Do not re-use : N·m (kg-m, in-lb) R p

: Apply rubber grease

NCL009

DISASSEMBLY AND ASSEMBLY 1. Remove damper assembly mounting bolts. 2. Remove gasket, damper rubber, plate, piston assembly, and piston spring from cylinder body. 3. Clean gasket contact surface on cylinder body and damper bracket with scrapers. CAUTION: Be careful not to scratch the contact surface.

INSPECTION ● ●

Check cylinder and piston contact surfaces for uneven wear, rust or damage. Replace if necessary. Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary.

CL-10

CLUTCH RELEASE MECHANISM

Withdrawal lever

Release bearing spring

L p

Release bearing

Clutch lever Release bearing spring Apply lithium-based grease including molybdenum disulphide

Spring pin

SCL819

REMOVAL AND INSTALLATION 1. Remove manual transaxle from vehicle. Refer to MT section “REMOVAL AND INSTALLATION”. 2. Remove release bearing by pulling bearing retainers outward.

SCL344

Tool

Retaining pin

Cavity of clutch housing

3. Align retaining pin with cavity of clutch housing and tap out retaining pin. CAUTION: ● Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement, or clutch damage may occur. Wipe the excess grease off completely, because it may cause the clutch components to slip and shudder. ● Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.

SCL149

INSPECTION ● ● ● ●

Replace the release bearing if it is seized, damaged, faulty in rotation direction, or has poor aligning function. Replace the withdrawal lever if its contact surface is worn abnormally. Replace the clutch lever if its contact surface is worn abnormally. Replace the dust seal if it is deformed or cracked.

CL-11

CLUTCH RELEASE MECHANISM LUBRICATION ●

Apply molykote BR2 plus

●

Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing.

SCL150

CL-12

CLUTCH DISC AND CLUTCH COVER

SEC. 300 Flywheel Clutch disc ● Do not clean in solvent. ● When installing, be careful that grease applied to main drive shaft does not adhere to clutch disc.

Clutch cover securing bolt 22 - 29 (2.3 - 2.9, 17 - 21)

. .

Clutch cover : Apply molykote BR2 plus : N·m (kg-m, ft-lb) SCL206

0.3 mm (0.012 in)

Clutch Disc INSPECTION Check clutch disc for wear of facing. Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)

SCL229

●

Runout of facing

Backlash of spline

●

Check clutch disc for backlash of spline and runout of facing. Maximum backlash of spline (at outer edge of disc): Model 215/225 0.9 mm (0.035 in) Runout limit: 1.0 mm (0.039 in) Distance of runout check point (from hub center): Model 215 102.5 mm (4.04 in) Model 225 107.5 mm (4.23 in) Check clutch disc for burns, discoloration or oil or grease contamination. Replace if necessary.

SCL221

INSTALLATION ● ●

Apply recommended grease to contact surface of spline portion. Too much lubricant may damage clutch disc facing.

CL-13

CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel INSPECTION AND ADJUSTMENT ●

Check clutch cover installed on vehicle for unevenness of diaphragm spring toe height. Uneven limit: Model 225 0.7 mm (0.028 in) Model 215 0.8 mm (0.031 in)

SCL504

FLYWHEEL INSPECTION Flywheel

● ●

Dial gauge

Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper. Check flywheel runout. Maximum allowable runout: Refer to EM section (“Inspection”, “CYLINDER BLOCK”).

SCL349

Except for CD20T engine models 3

INSTALLATION

6

KV30101600

●

1

●

4

5

●

2

Insert Tool into clutch disc hub when installing clutch cover and disc. Tighten bolts to specified torque. Tightening procedure a. Tighten all bolts, in numerical order, to 10 - 20 N·m (1.1 2.0 kg-m, 8 - 14 ft-lb). b. Tighten all bolts, in numerical order, to 22 - 29 N·m (2.3 2.9 kg-m, 17 - 21 ft-lb). Do not allow grease to contaminate clutch facing.

NCL023

For CD20T engine models KV30101600

7

5

1

2 4 8

9 3

6 NCL024

CL-14

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications CLUTCH CONTROL SYSTEM Type of clutch control

CLUTCH MASTER CYLINDER Hydraulic

Inner diameter

CLUTCH DAMPER

mm (in)

15.87 (5/8)

CLUTCH OPERATING CYLINDER

Inner diameter mm (in)

19.05 (3/4)

Inner diameter

mm (in)

17.46 (11/16)

CLUTCH DISC Unit: mm (in) Engine

QG16DE, QG18DE, SR20DE

CD20T

Model

215

225

216 x 153 x 3.5 (8.50 x 6.02 x 0.138)

225 x 150 x 3.5 (8.86 x 5.91 x 0.138)

7.3 - 7.9 (0.287 - 0.311) with 4,900 N (499.8 kg, 1,101.5 lb)

7.6 - 8.0 (0.299 - 0.315) with 3,923 N (400 kg, 882 lb)

Engine

QG16DE, QG18DE, SR20DE

CD20T

Model

L215K

L225K

Facing size (Outer dia. x inner dia. x thickness) Thickness of disc assembly with load

CLUTCH COVER

Full-load

N (kg, lb)

4,413 (450, 992)

CL-15

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment CLUTCH PEDAL Unit: mm (in) Applied model CD20T

RHD

LHD

145 - 150 (5.71 - 5.91)

140 - 145 (5.51 - 5.71)

153 - 158 (6.02 - 6.22)

140 - 145 (5.51 - 5.71)

QG16DE Pedal stroke “S” QG18DE SR20DE Pedal free play “A” (at pedal pad)

1 - 3 (0.04 - 0.12)

* : Measured from surface of dash reinforcement panel to surface of pedal pad.

CLUTCH DISC Unit: mm (in) Disc model

215

Wear limit of facing surface to rivet head

225 0.3 (0.012)

Runout limit of facing

1.0 (0.039)

Distance of runout check point (from hub center)

102.5 (4.04)

Maximum backlash of spline (at outer edge of disc)

107.5 (4.23) 0.9 (0.035)

CLUTCH COVER Unit: mm (in) Cover model Uneven limit of diaphragm spring toe height

CL-16

L215K

L225K

0.8 (0.031)

0.7 (0.028)

MANUAL TRANSAXLE SECTION

MT

CONTENTS PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7 NVH Troubleshooting Chart.........................................7 ON-VEHICLE SERVICE ..................................................8 Replacing Oil Seal .......................................................8 DIFFERENTIAL OIL SEAL ..........................................8 STRIKING ROD OIL SEAL..........................................8 Position Switch Check .................................................9 BACK-UP LAMP SWITCH...........................................9 NEUTRAL POSITION SWITCH ...................................9 REMOVAL AND INSTALLATION .................................10 Removal.....................................................................10 Installation..................................................................12 RS5F32A DESCRIPTION ...............................................................13 Cross-sectional View .................................................13 MAJOR OVERHAUL .....................................................14 Transaxle Gear Control .............................................14 Case Components .....................................................15 Gear Components .....................................................16 Shift Control Components .........................................17 DISASSEMBLY..............................................................18 REPAIR FOR COMPONENT PARTS............................21 Input Shaft and Gears ...............................................21 DISASSEMBLY ........................................................21 INSPECTION ...........................................................22 ASSEMBLY .............................................................23 Mainshaft and Gears .................................................24 DISASSEMBLY ........................................................24 INSPECTION ...........................................................26 ASSEMBLY .............................................................28 Final Drive..................................................................32 DISASSEMBLY ........................................................32

INSPECTION ...........................................................33 ASSEMBLY .............................................................33

Shift Control Components .........................................35 INSPECTION ...........................................................35 ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM ...........................................................36

Case Components .....................................................37 REMOVAL AND INSTALLATION ................................37 ADJUSTMENT ...............................................................39 Differential Side Bearing Preload ..............................39 ASSEMBLY....................................................................41 RS5F70A DESCRIPTION ...............................................................45 Cross-sectional View .................................................45 DOUBLE-CONE SYNCHRONIZER ............................46 MAJOR OVERHAUL .....................................................47 Transaxle Gear Control .............................................47 Case Components .....................................................48 Gear Components .....................................................49 Shift Control Components .........................................50 Final Drive Components ............................................51 DISASSEMBLY..............................................................52 Transaxle Case..........................................................52 Clutch Housing ..........................................................54 REPAIR FOR COMPONENT PARTS ...........................58 Input Shaft and Gears ...............................................58 DISASSEMBLY ........................................................58 INSPECTION ...........................................................59 ASSEMBLY .............................................................60 Mainshaft and Gears .................................................63 DISASSEMBLY ........................................................63 INSPECTION ...........................................................64 ASSEMBLY .............................................................66 Final Drive..................................................................71 PRE-INSPECTION ...................................................71 DISASSEMBLY ........................................................72 INSPECTION ...........................................................72

MT

CONTENTS ASSEMBLY .............................................................73 Shift Control Components .........................................74 INSPECTION ...........................................................74 ASSEMBLY....................................................................76 Clutch Housing ..........................................................76 Transaxle Case..........................................................80

(Cont’d) AVAILABLE C-RINGS ...............................................87 AVAILABLE SPACERS .............................................88 AVAILABLE WASHERS ............................................88 AVAILABLE SHIMS - DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM............88 INPUT SHAFT BRAKING MECHANISM .....................89 MAINSHAFT END PLAY ...........................................89

RS5F70A SERVICE DATA AND SPECIFICATIONS (SDS) ..........86 General Specifications - RS5F32A and RS5F70A....86 TRANSAXLE ...........................................................86 FINAL GEAR ...........................................................86

SERVICE DATA AND SPECIFICATIONS (SDS) .........90 Inspection and Adjustment - RS5F70A .....................90 GEAR END PLAY ....................................................90

RS5F32A SERVICE DATA AND SPECIFICATIONS (SDS) ..........87 Inspection and Adjustment - RS5F32A .....................87 GEAR END PLAY ....................................................87 CLEARANCE BETWEEN BAULK RING AND GEAR .....................................................................87 AVAILABLE CHECK PLUGS .....................................87 AVAILABLE SNAP RINGS ........................................87

MT-2

CLEARANCE BETWEEN BAULK RING AND GEAR .....................................................................90 AVAILABLE SNAP RINGS ........................................90 AVAILABLE C-RINGS ..............................................90 AVAILABLE ADJUSTING SHIMS ...............................91 AVAILABLE THRUST WASHER ................................92 AVAILABLE WASHERS ............................................92 AVAILABLE SHIMS - DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM ...........92

PREPARATION Special Service Tools

Special Service Tools Tool number Tool name

NCMT0001

Description

KV38107700 Preload adapter

Measuring turning torque of final drive assembly Measuring total turning torque Measuring clearance between side gear and differential case with washer Selecting differential side bearing adjusting shim (Use with KV38106000.)

NT087

KV38106000 Height gauge adapter (differential side bearing)

Selecting differential side bearing adjusting shim (Use with KV38107700 or KV38105900.) a: 140 mm (5.51 in) b: 40 mm (1.57 in) c: 16 mm (0.63 in) dia. d: M8 × 1.25P

NT418

KV32101000 Pin punch

Removing and installing retaining pin Removing and installing lock pin Removing selector shaft Removing welch plug a: 4 mm (0.16 in) dia. NT410

KV31100300 Pin punch

Removing and installing retaining pin a: 4.5 mm (0.177 in) dia.

NT410

ST30031000 Puller

NT411

Removing 3rd, 5th input gear Removing 3rd & 4th and 5th & Rev synchronizer hub Removing mainshaft rear bearing Removing 2nd gear, 5th gear bushing Removing 1st & 2nd synchronizer hub, 1st and 4th main gear Removing and installing differential side bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

NT411

Removing input shaft front and rear bearing Installing input shaft front and rear bearing Installing 5th input gear, 3rd main gear and 4th main gear Installing 1st & 2nd, 3rd & 4th and 5th & Rev synchronizer hub Installing 2nd gear bush, 5th gear bush, Rev gear bushing Installing mainshaft rear bearing a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia.

ST30021000 Puller

ST22730000 Puller

Removing mainshaft front and rear bearing inner race (F31A) Removing 5th main gear

a: 82 mm (3.23 in) dia. b: 30 mm (1.18 in) dia.

NT411

MT-3

PREPARATION Special Service Tools (Cont’d) Tool number Tool name

Description Removing differential side bearing a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia.

ST35321000 Drift

NT073

I Removing idler gear bearing outer race a: 250 mm (9.84 in) b: 160 mm (6.30 in)

KV381054S0 Puller

NT414

ST33200000 Drift

Installing mainshaft front bearing outer race (F31A) Installing mainshaft front bearing (F32A) a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. NT091

ST33230000 Drift

Removing differential oil seal Installing differential side bearing a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia.

NT084

ST33400001 Drift

Installing differential oil seal (F31A) a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia.

NT086

KV38102100 Drift

Installing differential oil seal a: 44 mm (1.73 in) dia. b: 24.5 mm (0.965 in) dia.

NT427

KV38100200 Drift

Installing differential oil seal a: 65 mm (2.56 in) dia. b: 49 mm (1.93 in) dia.

NT120

ST3072000 Drift

Installing side bearing outer race a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

NT115

MT-4

PREPARATION Special Service Tools (Cont’d) Tool number Tool name

Description Installing input shaft front and rear bearing a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.

ST22350000 Drift

NT065

ST22360002 Drift

Installing mainshaft rear bearing inner race (F31A) a: 29 mm (1.14 in) dia. b: 23 mm (0.91 in) dia.

NT065

ST22452000 Drift

Installing 3rd and 4th main gear Installing 5th gear bush Installing 5th & Rev synchronizer hub Installing Rev gear bush Installing mainshft rear bearing a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.

NT065

ST37750000 Drift

Installing input shaft oil seal Installing 5th synchronizer Installing mainshaft rear bearing Installing 5th main gear Installing 3rd & 4th synchronizer hub Installing striking rod oil seal Installing clutch housing dust seal a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia.

NT065

ST23860000 Drift

Installing 2nd gear bush a: 38 mm (1.50 in) dia. b: 33 mm (1.30 in) dia.

NT065

ST01530000 Drift

Installing 3rd & 4th and 1st & 2nd synchronizer hub Installing mainshaft front bearing a: 50 mm (1.97 in) dia. b: 41 mm (1.61 in) dia. NT065

KV38100130 Drift

Installing input shaft oil seal Installing 5th input gear a: 39 mm (1.54 in) dia. b: 30 mm (1.18 in) dia. NT065

ST30621000 Drift

Installing differential side bearing outer race (Use with ST30611000.) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia.

NT073

KV31103000 Drift

Installing differential oil seal (F32A) Right and left sides (Use with ST35325000.) a: 56 mm (2.20 in) dia. b: 49 mm (1.93 in) dia. NT105

MT-5

PREPARATION Special Service Tools (Cont’d) Tool number Tool name

Description Removing input shaft rear bearing Removing mainshaft rear bearing a: 22 mm (0.87 in) dia. b: 28 mm (1.10 in) dia.

ST33052000 Drift

NT431

ST30611000 Drift handle

Installing differential side bearing outer race (Use with ST30621000.) a: 15 mm (0.59 in) b: 335 mm (13.19 in) c: 25 mm (0.98 in) dia. d: M12 × 1.5P NT419

ST35325000 Drift handle

Installing differential oil seal (F32A) (Use with KV31103000.) a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: M12 × 1.5P

NT417

Commercial Service Tools Tool name

Description

Puller

Removing input shaft front bearing (F31A) Removing mainshaft rear bearing (F32A)

NT077

Drift

Installing differential side bearing inner race a: 12 mm (0.47 in) dia. b: 10 mm (0.39 in) dia.

NT065

Drift

Installing mainshaft front bearing inner race a: 26 mm (1.02 in) dia. b: 21 mm (0.83 in) dia. (F30A) a: 31 mm (1.22 in) dia. b: 26 mm (1.02 in) dia. (F32A) NT065

Drift

Installing differential side bearing inner race (F31A and F32A) a: 56 mm (2.20 in) dia. b: 50.5 mm (1.988 in) dia. NT065

Drift

Installing striking rod oil seal (F31A and F32A) a: 38 mm (1.50 in) dia. b: 32 mm (1.26 in) dia. NT065

MT-6

NCMT0002

2

O-RING (Worn or damaged)

MT-15, 48

CONTROL ROD (Worn)

MT-14, 47

2

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

MT-17, 50

3

SHIFT FORK (Worn)

MT-17, 50

3

3

GEAR (Worn or damaged)

MT-16, 49

3

BEARING (Worn or damaged)

MT-16, 49

3

BAULK RING (Worn or damaged)

MT-16, 49

3

INSERT SPRING, SHIFTING INSERT (Damaged)

MT-16, 49

1 2

1

NCMT0003

MT-15, 48

NVH Troubleshooting Chart

2

OIL SEAL (Worn or damaged)

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

2

MT-15, 48

NCMT0003S01

1

GASKET (Damaged)

MT-7

(Oil level is high.)

NVH Troubleshooting Chart

2

Refer to MA section (“Checking M/T Oil”, “CHASSIS AND BODY MAINTENANCE”).

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

1 3

1

(Wrong oil)

Reference page

Noise

Oil leakage

Hard to shift or will not shift

SUSPECTED PARTS (Possible cause)

Symptom Jumps out of gear

(Oil level is low.)

ON-VEHICLE SERVICE Replacing Oil Seal

Replacing Oil Seal ST33290001

NCMT0005

DIFFERENTIAL OIL SEAL

NCMT0005S01

1. 2. 3.

Drain gear oil from transaxle. Remove drive shafts — Refer to section FA. Remove differential oil seal.

4. I

Install differential oil seal. Apply multi-purpose grease to seal lip of oil seal before installing. Install drive shafts — Refer to section FA.

SMT563A

Drift

5.

.

Drift: LH side ST33400001 (F31A) KV31103000 and ST35325000 (F32A & F32V) RH side ST30720000 (F31A) LH and RH side KV38100200 (F70A) SMT564AB F32A Transmission case side

Clutch housing side

I

Install differential oil seal so that dimension “A” and “B” are within specifications. Unit: mm (in)

Oil seal

Item

A

F32A

5.9 - 6.1 (0.232 - 0.240)

F70A

0.5 (0.020) or less

B 0.5 (0.020) or less

SMT738B F70A Transaxle case side

Clutch housing side

Differential oil seal

Differential oil seal

SMT869D

STRIKING ROD OIL SEAL KV32101000

1. 2. I

Remove transaxle control rod from yoke. Remove retaining pin of yoke. Be careful not to damage boot.

SMT565A

MT-8

NCMT0005S02

ON-VEHICLE SERVICE Replacing Oil Seal (Cont’d) Drift

3.

Remove striking rod oil seal.

4. I

Install striking rod oil seal. Apply multi-purpose grease to seal lip of oil seal before installing.

SMT566A

Drift

SMT570A

Position Switch Check

F31A and F32A

NCMT0006

BACK-UP LAMP SWITCH I Neutral position switch connector

Back-up lamp switch harness connector

SMT715B

F70A Back-up lamp switch harness connector

Neutral position switch harness connector

NCMT0006S01

Check continuity Gear Position

Continuity

Reverse

Yes

Except reverse

No

NEUTRAL POSITION SWITCH I

NCMT0006S02

Check continuity. Gear position

Continuity

Neutral

Yes

Except neutral

No

NMT090

MT-9

REMOVAL AND INSTALLATION Removal

Removal 1. 2. 3. 4. 5.

Front

.

.

SMT653B

6.

Remove starter motor from transaxle.

7. 8. 9.

Remove shift control rod and support rod from transaxle. Drain gear oil from transaxle. Remove exhaust front tube.

Starter motor

Front .

NCMT0007S01

Remove battery negative terminal. Remove air duct. Disconnect clutch control cable from transaxle (GA16 models). Remove clutch operating cylinder from transaxle (except GA16 models). Disconnect back-up lamp switch, speedometer sensor, neutral position switch and ground harness connectors.

SMT654B

F31A and F32A Shift control rod

Shift support rod

SMT655B .

F70A .

Support rod

.

Control rod

NMT091

10. Draw out drive shafts from transaxle — Refer to section FA. Knuckle spindle upper nut

Drive shaft

SMT656B

MT-10

REMOVAL AND INSTALLATION Removal (Cont’d) .

11. Supprt engine by placing a jack under oil pan. CAUTION: Do not place jack under oil pan drain plug. 12. Remove rear and LH mounts.

F31A and F32A

SMT657B .

F70A

NMT092

13. Raise jack for access to lower housing bolts. Remove bolts. Lower jack.

Center member

Front

SMT658B

MT-11

REMOVAL AND INSTALLATION Installation

14. Remove bolts securing transaxle. 15. Lower transaxle while supporting it with a jack.

SMT659B

Installation I Tighten bolts securing transaxle. QG engine models:

NCMT0007S02

Bolt No.

Tightening torque N·m (kg-m, ft-lb)

 in mm (in)

1

30 - 40 (3.1 - 4.1, 22 - 30)

70 (2.76)

2

30 - 40 (3.1 - 4.1, 22 - 30)

80 (3.15)

3

16 - 21 (1.6 - 2.1, 12 - 15)

25 (0.98)

4

30 - 40 (3.1 - 4.1, 22 - 30)

30 (1.18)

Bolt No.

Tightening torque N·m (kg-m, ft-lb)

 in mm (in)

1

70 - 79 (7.1 - 8.1, 51 - 59)

55 (2.17)

2

70 - 79 (7.1 - 8.1, 51 - 59)

65 (2.56)

3

30 - 40 (3.1 - 4.1, 22 - 30)

35 (1.38)

4

30 - 40 (3.1 - 4.1, 22 - 30)

45 (1.77)

NMT094

SR engine models: : M/T to engine : Engine to M/T 

SMT661B

CD20T engine models: M/T to engine Engine (gusset) to M/T

Bolt No.

Tightening torque N·m (kg-m, ft-lb)

 in mm (in)

1

30 - 40 (3.1 - 4.1, 22 - 30)

120 (4.72)

2

30 - 40 (3.1 - 4.1, 22 - 30)

85 (3.35)

3

64 - 74 (6.5 - 7.5, 47.2 - 54.6)

75 (2.95)

4

16 - 21 (1.6 - 2.1, 12 - 15)

30 (1.18)

5

16 - 21 (1.6 - 2.1, 12 - 15)

25 (0.98)

Front gusset to engine

30 - 40 (3.1 - 4.1, 22 - 30)

35 (1.38)

Rear gusset to engine

30 - 40 (3.1 - 4.1, 22 - 30)

M10 × 1.25 (nut)



SMT740A

MT-12

DESCRIPTION

RS5F32A Cross-sectional View

Cross-sectional View

SMT123D

MT-13

RS5F32A

MAJOR OVERHAUL Transaxle Gear Control

Transaxle Gear Control SEC. 341

4.4 - 5.9 (0.45 - 0.60, 39.1 - 52.1)

12 - 15 (1.2 - 1.5, 9 - 11)

12 - 15 (1.2 - 1.5, 9 - 11)

22 - 29 (2.2 - 3.0, 16 - 22)

43 - 55 (4.4 - 5.6, 32 - 41)

18 - 24 (1.8 - 2.4, 13 - 17)

: Apply multi purpose grease : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) 14 - 18 (1.4 - 1.8, 10 - 13) NMT097 1 p 2 p 3 p 4 p 5 p 6 p

Control lever knob Boot Control lever socket Control lever Bushing Hand lever socket

7 p 8 p 9 p 10 p 11 p 12 p

Plate bolt Transaxle hole cover Support rod Plate Collar Bushing

MT-14

13 p 14 p 15 p 16 p 17 p 18 p

Collar Bushing Control rod Return spring Holder bracket Dynamic damper

MAJOR OVERHAUL

RS5F32A Case Components

Case Components

YMT004

MT-15

Input shaft front bearing 5th gear needle bearing 5th input gear Baulk ring

Coupling sleeve Spread ring Input shaft

MT-16

: N·m (kg-m, ft-lb) ★ : Select correct thickness L : Apply locking sealant p ✩ : Ensure correct direction ° : Apply gear oil : Do not re-use : Apply gear oil

3rd & 4th synchronizer hub Insert spring Baulk ring 4th main gear 4th gear bushing 5th main gear Spacer ★ Mainshaft rear bering C-ring ★ C-ring holder Snap ring Differential side bearing adjusting shim ★ Snap ring Differential side bearing L p

Snap ring ★ Mainshaft 1st main gear

Steel ball

Mainshaft front bearing

Pinion mate shaft Thrust washer

Pinion mate shaft . Side gear Thrust washer ★

2nd outer baulk ring 2nd gear synchronizer cone 2nd inner baulk. ring Speedometer drive gear Speedometer stopper Differential side bearing Differential case

Retaining pin 98 - 100 (10.0 - 11.0, 72 - 80)

Final gear

3rd gear synchronizer cone 3rd outer baulk ring Coupling sleeve

.

Spacer

Baulk ring 1st gear needle bearing . Reverse main gear (Coupling sleeve) ✩ Insert spring 1st & 2nd synchronizer hub

2nd main gear 2nd & 3rd bushing ° 5th gear synchronizer hub Spread ring 3rd main gear 5th stopper . 3rd inner baulk ring Snap ring ★ Input shaft bearing

Insert spring

Reverse idler spacer

Reverse idler gear Reverse idler bushing

MAJOR OVERHAUL RS5F32A

Gear Components

Gear Components

SEC. 322

NMT024

RS5F32A

MAJOR OVERHAUL

Shift Control Components

Shift Control Components SEC. 328

.

6.3 - 8.3 (0.64 0.85, 55.6 - 73.8) 12 - 16 (1.2 - 1.6, 9 - 12)

.

6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

.

: Apply gear oil : Do not re-use : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) L : p

★: ✩:

Apply locking sealant Select correct length Select correct part. Adjustment required NMT025

1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p

Check plunger Select return spring O-ring Check sleeve Striking lever Snap ring Striking interlock Reverse brake cam Reverse brake cam spring Check ball plug

11 p 12 p 13 p 14 p 15 p 16 p 17 p 18 p 19 p 20 p

Shift check ball Check spring Fork shaft support spring Fork shaft 5th shift fork Shifter cap 3rd & 4th shift fork Shifter cap 1st & 2nd shift fork Control bracket

MT-17

21 p 22 p 23 p 24 p 25 p 26 p 27 p 28 p 29 p

Control bracket pin Retaining pin Striking rod Retaining pin Yoke Reverse check plug Check ball (Large) Check ball (Small) Stopper pin

DISASSEMBLY

RS5F32A

1.

Remove case cover.

2.

Remove mainshaft bearing snap ring.

3.

Remove transmission case while slightly tilting it to prevent 5th shift fork from interfering with case.

4.

Draw out reverse idler spacer and fork shaft.

5. I

Remove 5th and 3rd & 4th shift forks. Be careful not to lose shifter cap.

Case cover

SMT664B

Snap ring

SMT665B

SMT666B

Fork shaft

SMT667B

5th shift fork

3rd & 4th shift fork

SMT188A

MT-18

DISASSEMBLY

.

RS5F32A

6.

Remove control bracket with 1st & 2nd shift fork.

7. a.

Remove gear components from clutch housing. Remove input shaft front bearing retainer securing bolts.

b.

Remove input shaft with bearing retainer, mainshaft assembly and reverse idler gear. Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side. Do not draw out reverse idler shaft from clutch housing because these fittings will be loose. When removing input shaft, be careful not to scratch oil seal lip with shaft spline.

1st & 2nd shift fork

Control bracket

SMT668B

Bearing retainer SMT669B

I I

SMT670B

c.

Remove final drive assembly.

8.

Remove oil pocket, shift check ball, check spring and check ball plug. Be careful not to lose check ball.

SMT671B

Check spring

I

Shift check ball Check ball plug

SMT648A

MT-19

DISASSEMBLY 9. KV320101000

I

RS5F32A

Drive retaining pin out of striking lever, then remove striking rod, striking lever and striking interlock. Ensure striking lever is positioned so that retaining pin does not foul clutch housing during removal.

SMT599A

I Oil seal

Be careful not to damage oil seal lip, when removing striking rod. If necessary, tape edges of striking rod.

SMT583

10. Remove reverse check plug, then detach reverse check spring and check balls. I Be careful not to lose check balls. I If the smaller ball does not come out, remove it together with check sleeve assembly.

SMT584

11. Remove check sleeve assembly.

SMT585

MT-20

RS5F32A

REPAIR FOR COMPONENT PARTS

Input Shaft and Gears

Input Shaft and Gears DISASSEMBLY 1.

Before disassembly, check 5th input gear end play.

Feeler gauge

Gears

End play mm (in)

5th input gear

0.18 - 0.31 (0.0071 - 0.0122)

End play Gear

Needle bearing

I

If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove — Refer to “Assembly”.

2.

Remove snap ring and 5th stopper.

3.

Remove 5th synchronizer, 5th input gear and 5th gear needle bearing.

4.

Remove snap ring of input shaft front bearing and input gear spacer.

SMT734A

SMT673B

5th input gear Set tool below 5th input gear 5th synchronizer hub ST30021000

SMT417CA

Snap ring

Spacer

Input shaft front bearing

SMT674B

MT-21

REPAIR FOR COMPONENT PARTS

RS5F32A

Input Shaft and Gears (Cont’d)

5. 6.

Pull out input shaft front bearing. Remove bearing retainer.

Puller

Bearing retainer Vise SMT675B

INSPECTION Gear and shaft I Check shaft for cracks, wear or bending. I Check gears for excessive wear, chips or cracks.

SMT602A

Synchronizer

Shifting insert

Spline area

I I I

Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.

NMT022

I

Baulk ring to gear clearance

Measure clearance between baulk ring and gear. Clearance between baulk ring and 5th input gear: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in)

SMT140

Bearing ● Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT148A

MT-22

REPAIR FOR COMPONENT PARTS

RS5F32A Input Shaft and Gears (Cont’d)

ASSEMBLY 1.

Assemble 5th synchronizer.

I

Be careful not to hook front and rear ends of spread spring to the same shifting insert.

2. 3. 4.

Install bearing retainer. Press on input shaft front bearing. Install input gear spacer.

SMT736A

Spread spring

Shifting insert

SMT761B

ST22350000

Bearing retainer

SMT731

5. Snap ring

Select correct snap ring of input shaft front bearing to minimize clearance of groove in input shaft and then install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap rings of input shaft front bearing: Refer to SDS, MT-87.

SMT708B

6. 7.

ST37750000

Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper. Measure gear end play as a final check — Refer to “Disassembly”.

5th synchronizer hub

SMT779A

MT-23

RS5F32A

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont’d)

8.

Select correct snap ring of 5th synchronizer hub to minimize clearance of groove in input shaft and install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Snap rings of 5th synchronizer: Refer to SDS, MT-87.

5th stopper Snap ring

SMT591

Mainshaft and Gears

End play

DISASSEMBLY

Gear

Feeler gauge

1. Before disassembly, measure gear end play. Gear end play:

Needle bearing or bushing

Gears

End play mm (in)

1st main gear

0.18 - 0.31 (0.0071 - 0.0122)

2nd-4th main gear

0.20 - 0.30 (0.0079 - 0.0118)

SMT605

●

If end play is not within the specified limit, disassemble and check the parts.

2.

Remove mainshaft rear bearing snap ring, C-ring holder and C-rings.

Snap ring

C-ring holder

SMT709B

Snap ring C-ring holder C-ring

Bearing

SMT676B

MT-24

RS5F32A

REPAIR FOR COMPONENT PARTS

Mainshaft and Gears (Cont’d)

3.

Remove mainshaft bearing and spacer.

4.

Remove 5th main gear.

5. I

Remove 4th main gear, 4th gear bushing and steel ball. Take care not to lose steel ball.

6.

Remove 3rd & 4th synchronizer and 3rd main gear.

Puller Suitable drift Mainshaft bearing

Spacer

SMT677B

ST22730000

Hook tool under flange as indicated by arrows

SMT593

4th main gear

Bushing

Steel ball

SMT418C

Drift

SMT679B

MT-25

REPAIR FOR COMPONENT PARTS

RS5F32A

Mainshaft and Gears (Cont’d)

7. I

Remove 2nd & 3rd bushing and 2nd gear. Take care not to lose the steel ball.

8.

Remove 1st & 2nd synchronizer hub and 1st main gear.

SMT740B

Drift

SMT681B

INSPECTION Gear and shaft I I

Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT604A

MT-26

REPAIR FOR COMPONENT PARTS

RS5F32A Mainshaft and Gears (Cont’d)

Synchronizer

Shifting insert

Spline area

I I I

Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for deformation.

NMT022

I

Baulk ring to gear clearance

I

Measure clearance between baulk ring and gear. Clearance between baulk rings and gears, for 1st and 4th gears only: Standard 1.0 - 1.35 mm (0.0394 - 0.0531 in) Wear limit 0.7 mm (0.028 in) 2nd and 3rd gears have inner and outer baulk rings and so have different measurements.

SMT140

I a. b.

c.

Inner baulk ring

Measure wear of 2nd and 3rd baulk ring. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions “A” and “B”. Standard: A 0.7 - 0.9 mm (0.028 - 0.035 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.

Synchronizer cone

SMT695B

MT-27

REPAIR FOR COMPONENT PARTS

RS5F32A

Mainshaft and Gears (Cont’d)

Outer baulk ring

Synchronizer cone SMT682B

Bearing I I

Make sure bearings roll freely and are free from noise, cracks, pitting or wear. The mainshaft front bearing cannot be re-used. It must be replaced once removed.

SPD715

ASSEMBLY 1. 2.

Install 1st gear needle bearing, 1st main gear and baulk ring. Press on 1st & 2nd synchronizer hub.

ST22452000

SMT689B

MT-28

REPAIR FOR COMPONENT PARTS

RS5F32A Mainshaft and Gears (Cont’d)

1st gear

I

Ensure correct fitting of 1st & 2nd synchronizer hub.

3.

Install 2nd synchronizer cone, outer & inner baulk ring and 1st & 2nd coupling sleeve.

4. I I

Install steel ball, 2nd main gear, 2nd & 3rd bushing. Apply gear oil to 2nd & 3rd gear bushing. Apply multi-purpose grease to steel ball before installing it. 2nd & 3rd bushing has a groove in which steel ball fits.

2nd gear

SMT701B

SMT683B

2nd & 3rd gear bushing 2nd gear

I

Steel ball

SMT680B

MT-29

REPAIR FOR COMPONENT PARTS

RS5F32A

Mainshaft and Gears (Cont’d)

5. 6.

Install 3rd main gear, synchronizer cone, and outer & inner baulk ring. Press on 3rd & 4th synchronizer hub.

7. I

Install 3rd & 4th coupling sleeve and 4th baulk ring. Ensure correct fitting of 3rd & 4th synchronizer hub.

8. I

Install steel ball, 4th bushing and 4th main gear. Apply multi-purpose grease to steel ball before installing it. 4th bushing has a groove in which steel ball fits.

ST37750000

SMT690B

4th gear

3rd gear

SMT702B

I

Steel ball

SMT691B

MT-30

REPAIR FOR COMPONENT PARTS

RS5F32A Mainshaft and Gears (Cont’d)

9.

Press on 5th main gear.

ST37750000

SMT692B

Mainshaft rear bearing Mainshaft adjusting spacer

Mainshaft

10. Install spacer and measure distance “C”. 11. Select proper mainshaft bearing spacer to give correct bearing distance. Bearing distance “C”: 230.15 - 230.25 mm (9.0610 - 9.0649 in) Spacers available: Refer to SDS, MT-88.

SMT693B

12. Press on mainshaft rear bearing.

ST22360002

SMT694B

MT-31

REPAIR FOR COMPONENT PARTS

RS5F32A

Mainshaft and Gears (Cont’d)

13. Select proper C-ring to minimize clearance of groove in mainshaft and install it. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Mainshaft C-rings: Refer to SDS, MT-87.

Snap ring C-ring holder C-ring

Bearing

SMT676B

14. Install C-ring holder and snap ring. 15. Measure gear end play as a final check — Refer to “Disassembly”. C-ring

SMT712B

Final Drive DISASSEMBLY

ST30031000

Drift

1.

Remove final gear.

2. 3. I

Remove speedometer drive gear by cutting it. Press out differential side bearings. Be careful not to mix up the right and left bearings.

4. 5.

Drive out retaining pin and draw out pinion mate shaft. Remove pinion mate gears and side gears.

SMT647A

SMT699B

MT-32

REPAIR FOR COMPONENT PARTS

RS5F32A Final Drive (Cont’d)

INSPECTION Gear, washer, shaft and case I I

Check mating surfaces of differential case, side gears and pinion mate gears. Check washers for wear.

SMT083A

Bearing I I

Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.

SPD715

ASSEMBLY 1.

Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.

2. I

Insert pinion mate shaft. When inserting, be careful not to damage pinion mate thrust washers.

3.

Measure clearance between side gear and differential case with washers using the following procedure: Set Tool and dial indicator on side gear. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears. Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 in) If not within specification, adjust clearance by changing thickness of side gear thrust washers.

SMT839

SMT840

Dial gauge

KV38107700

a. b.

c. SMT610A

MT-33

REPAIR FOR COMPONENT PARTS

RS5F32A

Final Drive (Cont’d)

Side gear thrust washers: Refer to SDS, MT-88.

SMT611A

4. I

Install retaining pin. Make sure that retaining pin is flush with case.

5. I 6.

Install final gear. Apply locking sealant to final gear fixing bolts before installing them. Install speedometer drive gear.

7.

Press on differential side bearings.

SMT699B

Chamfer

SMT609A

Drift

SMT648

MT-34

REPAIR FOR COMPONENT PARTS

RS5F32A Shift Control Components

Shift Control Components

Striking rod

INSPECTION I

Check contact surface and sliding surface for wear, scratches, projections or other damage.

Control bracket

Shift fork and shifter cap

SMT703B

SMT727B

MT-35

REPAIR FOR COMPONENT PARTS

RS5F32A

Shift Control Components (Cont’d)

ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM 1. I

Control bracket

Install striking lever & rod, striking interlock assembly and control bracket on clutch housing exactly. When installing control bracket on clutch housing, assure protrusion beneath bracket is correctly seated.

Clutch housing SMT774B

2.

Measure maximum height “H” while shifting from neutral to reverse position. Maximum height “H”: 67.16 - 67.64 mm (2.6441 - 2.6630 in)

3. 4.

Remove control bracket from clutch housing. Measure clearance “C” between reverse brake cam and striking lever at reverse position. Clearance “C”: 0.05 - 0.125 mm (0.0020 - 0.0044 in) If height “H” and clearance “C” are not within specifications, replace control bracket, striking lever and striking interlock assembly as a set.

1st & 2nd shifter

Height gauge

1st & 2nd shifter Striking lever

Control bracket fitting surface

.

Reverse brake cam SMT728B

5.

Reverse brake cam Striking lever

SMT729B

MT-36

REPAIR FOR COMPONENT PARTS

RS5F32A Case Components

Case Components REMOVAL AND INSTALLATION Input shaft oil seal

Drift SMT660A

I

Apply multi-purpose grease to seal lip of oil seal before installing.

KV38102100

SMT751BA

Input shaft rear bearing 1.

Remove welch plug from transmission case.

2.

Remove input shaft rear bearing by tapping it from welch plug hole.

3. I

Install welch plug. Apply recommended sealant to mating surface of transmission case.

SMT705B

SMT704B

SMT705B

MT-37

REPAIR FOR COMPONENT PARTS

RS5F32A

Case Components (Cont’d)

4.

Install input shaft rear bearing.

SMT706B

Mainshaft front bearing and oil channel 1.

Remove mainshaft front bearing retainer.

2. 3.

Remove mainshaft front bearing. Remove oil channel.

4. I

Install oil channel. Ensure that oil groove in oil channel always faces toward oil pocket when installing it on clutch housing.

5. 6. I

Install mainshaft front bearing. Install mainshaft front bearing retainer. Apply locking sealant to thread of screw before installation.

Bearing retainer

SMT707B

Mainshaft front bearing SMT714B

Toward oil pocket

Oil groove

SMT595

Drift SMT752BA

MT-38

RS5F32A

ADJUSTMENT

Differential Side Bearing Preload

Differential Side Bearing Preload If any of the following parts are replaced, adjust differential side bearing preload. I Differential case I Differential side bearing I Clutch housing I Transmission case

1.

Remove differential side bearing outer race (transmission case side) and shim.

2. 3. 4. I

Reinstall differential side bearing outer race without shim. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque.

ST33290001

SMT645

SMT646A

5. Set dial indicator on front end of differential case. 6. Insert Tool all the way into differential side gear. 7. Move Tool up and down and measure dial indicator deflection. 8. Select shim of proper thickness using SDS table as a guide. Differential side bearing adjusting shims: Refer to SDS MT-88.

KV38106000

KV38107700

SMT454

MT-39

ADJUSTMENT

RS5F32A

Differential Side Bearing Preload (Cont’d)

9. 10. a. b. I

Install selected shim and differential side bearing outer race. Check differential side bearing turning torque. Install final drive assembly on clutch housing. Install transmission case on clutch housing. Tighten transmission case fixing bolts to the specified torque. Page MT-15

c.

Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 2.9 - 6.9 N·m (30 - 70 kg-cm, 26 - 61 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. Changes in turning torque of final drive assembly per revolution should be within 1.0 N·m (10 kg-cm, 8.7 in-lb) without binding.

KV38107700

I I I SMT600

MT-40

ASSEMBLY Cellophane tape

Striking rod

RS5F32A

1. I

Install striking rod, lever and interlock. When inserting striking rod into clutch housing, tape edges of striking rod to avoid damaging oil seal lip.

2. 3.

Install reverse check sleeve assembly. Install check balls, reverse check spring and reverse check plug.

Oil seal SMT586

SMT584

4. Suitable bar

Vice

SMT688

Check spring

Check reverse check force. Reverse check force: 4.9 - 7.4 N·m (50 - 75 kg-cm, 43 - 65 in-lb) I If not within specification, select another check plug having a different length and reinstall it. Available reverse check plugs: Refer to SDS MT-87. 5. Install selected reverse check plug. I Apply locking sealant to thread of plug before installing it. 6. 7.

Install check ball plug, shift check ball and check spring. Install oil pocket.

8. a.

Install gear components onto clutch housing. Install final drive assembly.

Shift check ball Check ball plug

SMT648A

SMT671B

MT-41

ASSEMBLY b. I I

RS5F32A

Install input shaft assembly with bearing retainer, mainshaft assembly and reverse idler gear. Be careful not to damage oil seal lip with splines of input shaft while shaft is being inserted into clutch housing. Be careful not to damage oil channel when inserting mainshaft into clutch housing.

.

SMT670B

c.

Install input shaft front bearing retainer.

9.

Apply grease to shifter caps, then install it to control bracket. Install control bracket with 1st & 2nd shift fork.

Bearing retainer .

SMT669B

SMT666

I

Ensure control bracket is seated correctly on clutch housing. 10. Install 3rd & 4th and 5th shift forks. Control bracket

Clutch housing SMT774B

11. Insert fork shaft. I Apply multi-purpose grease to support spring before installing. 12. Install reverse idler spacer.

SMT596

MT-42

ASSEMBLY Apply sealant continuously

RS5F32A

13. Apply recommended sealant to mating surface of clutch housing.

SMT587

14. Install transmission case on clutch housing.

SMT666B

15. Install mainshaft front bearing snap ring.

Snap ring

SMT665B

16. Tap mainshaft with a soft hammer to ensure mainshaft rear bearing snap ring contacts the surface of transmission case.

SMT758B

MT-43

ASSEMBLY

RS5F32A

17. Select case cover using the following procedure. a. Measure distance between case cover fitting surface and mainshaft rear bearing outer race. Clearance “C” between the end of case cover and main shaft rear bearing outer race (Main shaft end play): 0 - 0.1 mm (0 - 0.004 in) b. Select case cover so that clearance “C” will be specified clearance. Case cover: Refer to SDS MT-89.

Case cover

Thickness of cover

End play

SMT775B

18. Install O-ring and case cover on transmission case. I Apply recommended sealant to mating surface of transmission case.

Case cover

SMT664B

MT-44

NCMT0004

RS5F70A

DESCRIPTION

Cross-sectional View

Cross-sectional View

NCMT0004S01

Clutch housing 3rd input gear 3rd & 4th synchronizer 4th input gear 5th input gear Reverse idler gear Input shaft front bearing

Input shaft rear bearing

Input shaft

Mainshaft Mainshaft rear bearing .

Mainshaft front bearing

Sub-gear

Reverse main gear 5th & reverse synchronizer assembly 5th main gear 4th main gear

3rd main gear 2nd main gear Differential side bearing

1st & 2nd synchronizer assembly 1st main gear

Speedometer drive gear

Differential side bearing

Differential case Final gear

SMT834D

MT-45

DESCRIPTION

RS5F70A

Cross-sectional View (Cont’d)

DOUBLE-CONE SYNCHRONIZER 2nd main gear

NCMT0004S0101

Double-cone synchronizer is adopted for 1st and 2nd gears to reduce operating force of the shift lever.

Clutch gear coupling Sleeve Synchronizer hub

Outer baulk ring Synchronizer cone Inner baulk ring SMT837D

MT-46

NCMT0008

RS5F70A

MAJOR OVERHAUL

Transaxle Gear Control

Transaxle Gear Control

NCMT0008S01

4.4 - 5.9 (0.45 - 0.60, 39 - 52)

12 - 15 (1.2 - 1.5, 9 - 11) 22 - 29 (2.2 - 3.0, 16 - 22)

18 -24 (1.8 -2.4, 13 - 17)

12 - 15 (1.2 - 1.5, 9 - 11) Apply multi-purpose grease. N·m (kg-m, in-lb) N·m (kg-m, ft-lb)

29 - 37 (3.0 - 3.8, 21 - 27)

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

Control lever knob Boot Finisher Control lever bracket Dust cover Socket Control lever

14 - 18 (1.4 - 1.8, 10 -13)

8. 9. 10. 11. 12. 13. 14.

O-ring O-ring Ring spring Bearing seat Seat Return spring Control rod

MT-47

SMT135D

15. 16. 17. 18. 19. 20. 21.

Bush Collar Bush Bracket Bush Collar Washer

RS5F70A

MAJOR OVERHAUL Case Components

Case Components

=NCMT0008S02

3.7 - 5.0 (0.38 - 0.51, 33 - 44)

16 - 22 (1.6 - 2.1, 12 - 16)

6.3 - 8.3 (0.64 - 0.85, 56 - 74)

23 - 33 (2.3 - 3.4, 17 - 25) 10 - 19 (1.0 - 2.0, 87 - 174)

7.4 - 9.7 (0.75 - 0.99, 65 - 86)

N·m (kg-m, in-lb) N·m (kg-m, ft-lb) Apply genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

29 - 33 (3.0 - 3.4, 22 - 25) 23 - 33 (2.3 - 3.4, 17 - 25)

7.4 - 9.7 (0.75 - 0.99, 65 - 86)

Apply locking sealant. Apply gear oil. Select with proper thickness.

25 - 34 (2.5 - 3.5, 18 - 25)

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

Clutch housing Welch plug Oil pocket Check plug Input shaft oil seal Oil channel Mainshaft front bearing Bearing retainer Magnet Reverse idler gear rear thrust washer 11. Reverse idler gear 12. Reverse idler gear bearing

13. Reverse idler gear front thrust washer 14. O-ring 15. Reverse idler gear shaft 16. Snap ring 17. Reverse switch 18. Filler plug 19. Side cover gasket 20. Side cover 21. Welch plug 22. Mainshaft bearing snap ring 23. Mainshaft bearing adjusting shim 24. O-ring

MT-48

SMT640D

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.

Rear cover Differential oil seal Drain plug PNP switch Transmission case Oil gutter Welch plug Magnet Boot Striking rod oil seal Welch plug Differential oil seal O-ring Speedometer pinion (If so equipped)

RS5F70A

MAJOR OVERHAUL

Gear Components

Gear Components

=NCMT0008S03

Apply gear oil. Select with proper thickness. SMT641D

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Reverse idler gear rear thrust washer Reverse idler gear Reverse idler gear bearing Reverse idler gear front thrust washer O-ring Reverse idler gear shaft Snap ring Input shaft front bearing Input shaft 3rd gear needle bearing 3rd input gear 3rd gear baulk ring Coupling sleeve Spread spring Shifting insert Coupling sleeve Spread spring 4th gear C-ring 4th gear needle bearing 4th gear baulk ring 4th input gear 5th gear front C-ring 5th input gear

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.

5th gear rear C-ring C-ring holder Input shaft rear bearing Oil channel Input shaft rear bearing adjusting shim Mainshaft front bearing Mainshaft 1st gear needle bearing 1st main gear 1st inner baulk ring 1st synchronizer cone 1st outer baulk ring 1st & 2nd synchronizer hub Coupling sleeve Insert spring 2nd gear bushing 2nd gear needle bearing 2nd gear outer baulk ring 2nd gear synchronizer cone 2nd inner baulk ring 2nd main gear 3rd main gear Spacer

MT-49

47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.

Mainshaft adjusting shim 4th main gear 5th gear bushing 5th gear needle bearing 5th main gear 5th gear baulk ring Spread spring Shifting insert 5th & reverse synchronizer hub Spread spring Coupling sleeve Reverse gear bush Reverse gear needle bearing Reverse gear baulk ring Reverse main gear Sub-gear Sub-gear washer Snap ring Mainshaft thrust washer Mainshaft rear bearing Mainshaft C-ring C-ring holder Snap ring

RS5F70A

MAJOR OVERHAUL Shift Control Components

Shift Control Components

=NCMT0008S04

16 - 21 (1.6 -2.1, 12 - 15)

N·m (kg-m, ft-lb) Apply genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.

16 - 22 (1.6 - 2.2, 12 - 16)

16 - 21 (1.6 - 2.1, 12 - 15)

Apply gear oil.

16 - 21 (1.6 - 2.1, 12 - 15)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Clutch housing 3rd & 4th bracket 3rd & 4th shift fork Retaining pin Check ball Check pin Check spring Check plug Stopper ring 3rd & 4th fork rod Selector shaft pin Selector 5th & reverse bracket Reverse switch bracket Retaining pin 5th & reverse shift fork

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

SMT642D

Interlock plunger Check ball Interlock pin Stopper ring 5th & reverse fork rod Striking lever Retaining pin 1st & 2nd bracket 1st & 2nd shift fork Check ball 1st & 2nd fork rod Transaxle case Check ball Check spring Check plug

MT-50

32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.

Reverse gate Return spring Steel ball Reverse gate Return bearing Selector arm Bushing Welch plug Selector shaft Striking yoke Retaining pin Striking rod Dust boot Striking rod oil seal Welch plug

RS5F70A

MAJOR OVERHAUL

Final Drive Components

Final Drive Components Apply locking sealant

=NCMT0008S05

98 - 108 (10.0 - 11.0, 72 - 80)

N·m (kg-m, ft-lb) Select with proper thickness.

SMT643D

1. 2. 3. 4. 5.

Differential shim Differential Differential Final gear Differential

side bearing adjusting side bearing outer race side bearing

6. 7. 8. 9. 10.

Speedometer drive gear Speedometer stopper Differential side bearing Differential side bearing outer race Pinion mate thrust washer

case

MT-51

11. 12. 13. 14. 15.

Pinion mate gear Side gear thrust washer Side gear Pinion mate shaft Lock pin

NCMT0009

DISASSEMBLY

RS5F70A

Transaxle Case

Transaxle Case

Reverse switch PNP switch

Filler plug

NCMT0009S01

1.

Remove reverse switch, PNP switch, drain plug, and filler plug from transaxle case.

2. 3. 4.

Remove snap rings from reverse idler shaft. Remove side cover and rear cover from case. Remove O-ring and mainshaft bearing adjusting shim.

5. a. b.

Remove reverse idler gear shaft. Attach bolt (M6) to thread of reverse idler gear shaft end. Pull out the attached bolt, and remove reverse idler gear shaft from case. Remove reverse idler gear, thrust washer, and bearing from case.

Drain plug SMT648D Snap ring

Rear cover

Side cover

SMT644D

Bolt (M6)

6.

SMT645D

7.

Remove snap ring of mainshaft bearing from case.

8.

Remove check plugs, springs, and check balls from case.

Flat-head screwdriver Mainshaft rear bearing snap ring

SMT646D

Check plug

SMT647D

MT-52

DISASSEMBLY

RS5F70A Transaxle Case (Cont’d)

Clutch housing

Transaxle case

9. Remove mounting bolts. 10. Remove input shaft rear bearing adjusting shim from transaxle case.

SMT649D

11. Remove oil gutter from case.

Oil gutter

SMT650D

12. Remove differential side bearing outer race and adjusting shim from case.

SMT651D

13. Remove differential oil seal from case.

SMT653D

14. Remove welch plugs from case.

SMT839D

MT-53

DISASSEMBLY

RS5F70A

Clutch Housing

Clutch Housing

NCMT0009S02

1. 2. 3.

Remove transaxle case from clutch housing. Remove magnet from housing. Remove check plugs, check springs, check pins, and check balls from housing.

4.

Remove 3rd & 4th bracket retaining pin.

5. 6. 7.

Remove 3rd & 4th shift fork stopper ring. Remove 3rd & 4th fork rod. Remove 3rd & 4th shift fork and bracket.

8. 9.

Remove interlock plunger and check ball. Remove 5th & reverse bracket stopper ring.

Check plug Clutch housing

SMT654D

3rd & 4th shift fork 3rd & 4th bracket

SMT656D

Stopper ring

3rd & 4th shift fork 3rd & 4th bracket

SMT655D

Stopper ring

5th & reverse bracket

Check ball Interlock plunger SMT658D

5th & reverse shift fork 5th & reverse bracket

10. Remove retaining pin from 5th & reverse shift fork and reverse switch bracket. 11. Remove 5th & reverse fork rod. 12. Remove interlock pin from 5th & reverse fork rod. 13. Remove reverse switch bracket and 5th & reverse bracket.

SMT657D

MT-54

RS5F70A

DISASSEMBLY

Clutch Housing (Cont’d) 1st & 2nd shift fork

14. 15. 16. 17.

Remove check ball from housing. Remove retaining pin for 1st & 2nd shift fork and bracket. Remove 1st & 2nd fork rod. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd bracket.

1st & 2nd bracket Check balls SMT659D

Mainshaft assembly

18. Remove both input shaft and mainshaft assemblies from housing.

Input shaft assembly SMT660D

Final drive assembly

Oil pocket

19. Remove final drive assembly from housing. 20. Remove oil pocket from housing.

SMT661D

21. Remove mainshaft bearing retainer from housing. 22. Cut off oil channel using a cutter as shown in the figure. Cut area Oil channel

Mainshaft bearing retainer

SMT662D

23. Remove mainshaft front bearing from housing.

Mainshaft front bearing

SMT663D

MT-55

DISASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

24. Using a magnet or other suitable tool, remove retaining pin from selector shaft.

Selector Selector pin

SMT664D

25. Remove selector shaft and plug, then remove selector. Selector

Selector shaft

SMT665D

26. Remove reamer bolt, then remove selector leaf spring, return spring, steel ball, reverse gate, selector arm, bearing, and bushing. CAUTION: Be careful not to lose the steel ball.

Selector leaf spring

Return spring SMT666D

27. Remove retaining pin and plug from striking lever. 28. Remove striking rod, then striking lever from housing.

Striking lever

SMT667D

Flat-head screwdriver

29. Using a flat-head screwdriver or other suitable tool, remove dust seal, input shaft oil seal, and striking rod oil seal from housing. CAUTION: When removing dust and oil seals, be careful not to damage mounting surfaces of dust seal and oil seal.

Flat-head screwdriver

Input shaft oil seal Dust seal

SMT668D

MT-56

RS5F70A

DISASSEMBLY

Clutch Housing (Cont’d)

30. Remove differential oil seal from housing.

Differential oil seal

SMT669D

31. Remove differential side outer race from housing.

Differential side bearing outer race

SMT670D

MT-57

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears

Input Shaft and Gears

Feeler gauge

DISASSEMBLY 1.

I Input shaft assembly

SMT759D

2.

Remove oil channel from input shaft rear bearing.

3.

Press out input shaft rear bearing.

4. 5.

Remove C-ring holder. Remove 5th gear rear C-ring.

6. 7.

Remove 5th input gear from input shaft. Remove 5th gear front C-ring.

Oil channel

Input shaft SMT671D

Input shaft rear bearing

SMT672D

C-ring holder

Flat-head screwdriver 5th gear rear C-ring SMT673D

5th input gear

NCMT0010

Before disassembly, measure the end plays of 3rd and 4th input gears. Gear end play: Refer to SDS, MT-90. If end play is not within specification, disassemble and check the parts.

SMT674D

MT-58

RS5F70A

REPAIR FOR COMPONENT PARTS

Input Shaft and Gears (Cont’d)

8. 3rd & 4th synchronizer hub assembly

Remove 4th input gear, baulk ring, 4th gear needle bearing, and 4th gear C-ring from input shaft. 9. Press out both 3rd & 4th synchronizer hub assembly and 3rd input gear from input shaft. 10. Remove 3rd gear needle bearing.

3rd input gear SMT675D

11. Press out input shaft front bearing from input shaft. Input shaft front bearing

SMT676D

INSPECTION Gear and Shaft I I

NCMT0011 NCMT0011S01

Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT693D

Synchronizers I I I

NCMT0011S02

Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.

SMT637A

I

If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.

SMT867D

MT-59

RS5F70A

REPAIR FOR COMPONENT PARTS Input Shaft and Gears (Cont’d)

I

Fixed

3rd & 4th coupling sleeve

Measure the movement (play, dimension “L”) of 3rd & 4th coupling sleeve with their end fixed and the other end lifted as shown in the figure. If the movement exceeds specification, replace the sleeve.

Coupling sleeve Dimension “L”

3rd & 4th

Length “L” 0 - 0.95 mm (0 - 0.0374 in)

SMT841D

I

Baulk ring to gear clearance

Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.

SMT140

Bearing I

NCMT0011S03

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT148A

ASSEMBLY 1. 2.

NCMT0012

Press on input shaft front bearing. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.

Input shaft front bearing Input shaft

SMT696D

3.

Install spread spring, shifting insert, and 3rd & 4th synchronizer hub onto 3rd & 4th coupling sleeve. I Pay attention to the shape of spread spring and shifting insert for correct assembly. Do not install spread spring hook onto the same shifting insert. CAUTION: Do not reuse 3rd & 4th synchronizer hub.

Shifting insert (3rd & 4th) (5th & reverse)

Flat shape

R-shape

Spread spring

Shifting insert

SMT694D

MT-60

REPAIR FOR COMPONENT PARTS

RS5F70A Input Shaft and Gears (Cont’d)

I

Install synchronizer hub with its three grooves facing the front side (3rd input gear side).

I

Install 3rd & 4th coupling sleeve with its chamfered surface facing the 4th input gear side.

4.

Position bearing replacer to the front side of input shaft front bearing. Align grooves of shifting insert and 3rd gear baulk ring. Then, press it onto 3rd & 4th synchronizer hub assembly using a drift. Install 4th gear C-ring onto input shaft.

Front SMT695D

4th input gear

3rd input gear

SMT699D

3rd & 4th synchronizer hub assembly

I 5.

SMT698D

6. Feeler gauge 3rd & 4th synchronizer hub assembly

7.

Measure the end play of 3rd & 4th synchronizer hub, and check if it is within allowable specification below. End play specification: 0 - 0.06 mm (0 - 0.0024 in) If not within specification, adjust the end play by changing thickness of 4th gear C-ring. Available C-ring: Refer to SDS, MT-90.

4th gear C-ring SMT700D

8. 5th gear front C-ring 4th gear needle bearing

9.

Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring. Install 4th input gear.

4th gear baulk ring

SMT701D

MT-61

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

10. Position 5th input gear as shown in the figure, and install it on input shaft.

5th input gear

4th input gear

SMT703D

5th input gear 4th input gear

11. Install 5th input gear. CAUTION: Do not reuse 5th input gear. 12. Install 5th gear rear C-ring onto input shaft.

SMT702D

5th input gear

13. Measure the end play of 5th input gear, and check if it is within the allowable specification below. End play specification: 0 - 0.06 mm (0 - 0.0024 in) 14. If not within specification, adjust the end play by changing thickness of the 5th gear rear C-ring. Available C-ring: Refer to SDS, MT-90.

5th rear C-ring Feeler gauge

SMT704D

Input shaft rear bearing C-ring holder

15. Install C-ring holder onto 5th gear rear C-ring. CAUTION: Do not reuse C-ring holder. 16. Install input shaft rear bearing. CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.

SMT705D

17. Install oil channel onto input shaft. 18. Measure gear end play as a final check. Refer to, MT-58.

Oil channel

Input shaft SMT671D

MT-62

RS5F70A

REPAIR FOR COMPONENT PARTS

Mainshaft and Gears

Mainshaft and Gears

Mainshaft assembly

DISASSEMBLY 1.

I

NCMT0013

Before disassembly, measure gear end play. Gear end play: Refer to SDS, MT-90. If end play is not within the specificed limit, disassemble and check the parts.

Feeler gauge SMT760D

2.

Remove snap ring.

3.

Remove C-ring holder and mainshaft C-ring.

4.

Press out mainshaft rear bearing from mainshaft.

5. 6.

Remove mainshaft thrust washer. Remove snap ring from mainshaft. Then, remove reverse main gear assembly, reverse gear needle bearing, and reverse gear baulk ring.

Snap ring

SMT677D

C-ring holder

Mainshaft C-ring

SMT678D

Mainshaft rear bearing

SMT679D

Mainshaft thrust washer

Reverse main gear assembly

SMT680D

MT-63

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d) Reverse gear bush 5th & reverse synchronizer hub assembly

7.

8.

Place bearing replacer between 5th & reverse synchronizer hub and 5th main gear, and press out both reverse gear bushing and 5th & reverse synchronizer assembly. Remove 5th main gear, 5th gear baulk ring, and 5th gear needle bearing.

SMT681D

9.

Place bearing replacer between 3rd and 4th main gears, and press out both 5th gear bushing and 4th main gear.

5th gear bush 4th main gear

SMT682D

10. Remove mainshaft adjusting shim and spacer. 11. Place bearing replacer between 2nd main gear and 1st & 2nd synchronizer hub, and press out both 3rd and 2nd main gears. 3rd main gear Bearing replacer 2nd main gear

SMT683D

2nd gear bush 1st & 2nd synchronizer hub

12. Remove 2nd double cone assembly, 2nd gear bushing, and coupling sleeve assembly. 13. Place bearing replacer on 1st gear front side, and press out all of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main gear, and 1st double cone. 14. Remove 1st gear needle bearing.

1st main gear SMT684D

INSPECTION Gear and Shaft I I

Check shaft for cracks, wear or bending. Check gears for excessive wear, chips or cracks.

SMT693D

MT-64

NCMT0014 NCMT0014S01

RS5F70A

REPAIR FOR COMPONENT PARTS

Mainshaft and Gears (Cont’d)

Synchronizers I I I

NCMT0014S02

Check spline area of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check insert springs for wear or deformation.

SMT637A

I

If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.

I

Measure the movement (play, dimension “L”) of 1st & 2nd coupling sleeve and 5th & reverse coupling sleeve with their end fixed and the other end lifted as shown in the figure. If the movement exceeds specification, replace the sleeve.

SMT867D Fixed

1st & 2nd coupling sleeve

Dimension “L”

Coupling sleeve Fixed

5th & reverse coupling sleeve

Dimension “L”

Length “L”

1st & 2nd

0 - 0.68 mm (0 - 0.0268 in)

5th & Reverse

0 - 0.89 mm (0 - 0.0350 in)

SMT868D

I

Baulk ring to gear clearance

Measure clearance between baulk ring and gear. Clearance between baulk ring and gear: Refer to SDS, MT-90.

SMT140

Bearing I

NCMT0014S03

Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

SMT148A

MT-65

RS5F70A

REPAIR FOR COMPONENT PARTS Mainshaft and Gears (Cont’d)

Outer baulk ring Inner baulk ring

Synchronizer cone

Synchronizer cone

SMT714CB

I a) b)

I

Measure wear of 1st and 2nd baulk ring. Place baulk rings in position on synchronizer cone. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions “A” and “B”. Standard: A 0.6 - 0.8 mm (0.024 - 0.031 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.

ASSEMBLY 1st gear needle bearing

1. 1st main gear

2.

NCMT0015

Install 1st gear needle bearing and 1st main gear onto mainshaft. Install 1st double cone assembly onto mainshaft.

Mainshaft SMT706D

3.

Install 1st & 2nd synchronizer hub with its three grooves facing the front side (1st main gear side) onto mainshaft. CAUTION: Do not reuse 1st & 2nd synchronizer hub.

Front SMT695D

MT-66

REPAIR FOR COMPONENT PARTS

RS5F70A Mainshaft and Gears (Cont’d)

4.

Install 1st & 2nd synchronizer hub.

5.

Install insert spring onto 1st & 2nd coupling sleeve.

6.

Install 1st & 2nd coupling sleeve with its chamfered surface facing the 1st main gear side onto 1st & 2nd synchronizer hub.

7.

Install 2nd gear bushing with its flange surface facing 1st & 2nd synchronizer hub side.

1st & 2nd synchronizer hub 1st gear double cone assembly

SMT707D

1st & 2nd coupling sleeve

SMT994BB

2nd main gear

1st main gear

1st & 2nd coupling sleeve

SMT708D

2nd gear bush

SMT709D

2nd main gear

8.

4th main gear 3rd main gear 2nd needle bearing

3rd main gear

2nd main gear

Install 2nd needle bearing, 2nd double cone assembly, and 2nd main gear onto mainshaft. 9. Position 3rd main gear as shown in the figure, and install it. CAUTION: Do not reuse 3rd main gear.

SMT710D

MT-67

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

10. Install spacer and mainshaft adjusting shim onto mainshaft. 11. Select a mainshaft adjusting shim suitable to satisfy the following specification of dimension “L” and install it onto mainshaft. Specification of dimension “L”: 151.35 - 151.45 mm (5.9586 - 5.9626 in) Available mainshaft adjusting shims: Refer to SDS, MT-91.

3rd main gear shim

151.35 - 151.45 mm (5.9586 - 5.9626 in)

Dimension “L”

SMT711D

12. Position 4th main gear as shown in the figure, and install it onto mainshaft. 5th main gear

3rd main gear

4th main gear

SMT713D

13. Install 4th main gear onto mainshaft. CAUTION: Do not reuse 4th main gear. 4th main gear

SMT712D

14. Install 5th gear bushing with its flange surface facing the 4th main gear side. 5th gear bush

SMT714D

MT-68

RS5F70A

REPAIR FOR COMPONENT PARTS

Mainshaft and Gears (Cont’d)

15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring onto mainshaft.

Reverse SMT761D

16. Being careful of the following points, install spread spring, shifting insert, and 5th & reverse synchronizer hub onto 5th & reverse coupling sleeve. I Pay attention to the shape of spread spring and shifting insert for correct assembly. Do not install spread spring hook onto the same shifting insert.

Shifting insert (3rd & 4th) (5th & reverse)

Flat shape

R-shape

Spread spring

Shifting insert

SMT694D

I

Install synchronizer hub with its three grooves facing the front side (5th main gear side). CAUTION: Do not reuse 5th & reverse synchronizer hub.

Front SMT695D

I

Reverse main gear

Install 5th & reverse coupling sleeve with its chamfered surface facing the reverse main gear side.

5th main gear

5th & reverse coupling sleeve

SMT716D

17. Install 5th & reverse synchronizer hub assembly.

5th & reverse synchronizer hub assembly

SMT715D

MT-69

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

Reverse gear bush

18. Install reverse gear baulk ring. 19. Install reverse gear bushing. 20. Install reverse gear needle bearing.

Reverse gear baulk ring

SMT717D

Reverse main gear

21. Install sub-gear, sub-gear washer, and snap ring onto reverse main gear. CAUTION: I Pay attention to direction of sub-gear washer. I Do not reuse snap ring.

Sub-gear washer

Sub-gear Reverse main gear

Sub-gear washer Snap ring

SMT718D

22. Install reverse main gear assembly onto mainshaft. 23. Select a thrust washer suitable to satisfy the following specification of dimension “M” (as shown in the figure), and install it onto mainshaft. Specification of dimension “M”: 244.20 - 244.30 mm (9.6142 - 9.6181 in) Available thrust washers: Refer to SDS, MT-92. 244.20 - 244.30 mm (9.6142 - 9.6181 in)

Thrust washer Dimension “M” SMT719D

24. Install mainshaft rear bearing.

Mainshaft rear bearing

SMT720D

MT-70

REPAIR FOR COMPONENT PARTS

RS5F70A Mainshaft and Gears (Cont’d)

Feeler gauge

Mainshaft C-ring

25. Install mainshaft C-ring. 26. Using feeler gauge, measure the end play of mainshaft rear bearing, and check if it satisfies the following specification. End play specification: 0 - 0.06 mm (0 - 0.0024 in) Available mainshaft C-rings: Refer to SDS, MT-91.

SMT721D

27. Install C-ring holder. C-ring holder

Mainshaft C-ring

SMT678D

28. Install snap ring. 29. Measure gear end play as a final check. Refer to, MT-63. CAUTION: I Do not reuse snap ring.

Snap ring

SMT677D

Final Drive

Dial gauge

PRE-INSPECTION I 1.

NCMT0036

Check the clearance between side gear and differential case as follows. Clean final drive assembly sufficiently to prevent side gear thrust washer, differential case, side gear, and other parts from sticking by gear oil.

SMT610AE

2. 3.

4. 5. SMT685D

Upright the differential case so that the side gear to be measured faces upward. Place final drive adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance. Clearance between side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) If not within specification, adjust the clearance by changing thrust washer thickness. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way.

MT-71

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

DISASSEMBLY

Chamfer

1. 2. I

NCMT0016

Remove mounting bolts. Then, separate the final gear from differential case. Make a notch and remove speedometer drive gear using a scraper or other suitable tool. Bearing replacer cannot be positioned unless speedometer drive gear is removed.

SMT609A

Puller

Puller

3. 4. 5.

Remove differential side bearing of final gear side. Turn differential case upside down, and remove differential side bearing of speedometer drive gear side. Remove speedometer stopper.

6.

Remove lock pins from pinion mate shaft.

7. 8.

Remove pinion mate shaft. Rotate pinion mate gear, and remove pinion mate gear, pinion mate thrust washer, side gear, and side gear thrust washer from differential case.

SMT840D

SMT689D

SMT839

INSPECTION Gear, Washer, Shaft and Case I I

NCMT0017 NCMT0017S01

Check side gear, side gear thrust washer, pinion mate shaft, pinion mate gear, pinion mate gear washer, and differential case. Check washers for wear.

SMT083A

MT-72

RS5F70A

REPAIR FOR COMPONENT PARTS

Final Drive (Cont’d)

Bearing I I

NCMT0017S04

Make sure bearings roll freely and are free from noise, cracks, pitting or wear. When replacing tapered roller bearing, replace outer and inner race as a set.

SPD715

ASSEMBLY 1. 2. 3.

NCMT0018

Apply gear oil to sliding area of differential case, each gear, and thrust washer. Install side gear thrust washer and side gear into differential case. Position pinion mate gear and pinion mate thrust washer diagonally, and install them into differential case while rotating.

SMT062A

4.

Insert pinion mate shaft into differential case.

SMT087A

5.

SMT685D

Upright the differential case so that its side gear to be measured faces upward. 6. Place preload adapter and dial gauge onto side gear. Move side gear up and down, and measure the clearance. 7. Turn differential case upside down, and measure the clearance between side gear and differential case on the other side in the same way. Clearance of side gear and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) Available differential thrust washers: Refer to SDS, MT-92. 8. Hammer the retaining pin into pinion mate shaft. CAUTION: Do not reuse retaining pin.

SMT750D

MT-73

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

9. Align and install speedometer drive gear into differential case. 10. Install speedometer stopper.

Speedometer drive gear

Installation direction

Alignment position

SMT842D

11. Install differential side bearing. 12. Turn differential case upside down, and install another differential side bearing on the other side in the same way. Speedometer drive gear

SMT751D

13. Install final gear into differential case. Apply sealant onto mounting bolts, and tighten them in order as shown in the figure with specified torque. Tightening torque: Refer to MT-48.

SMT752D

Shift Control Components INSPECTION I

NCMT0019

Check if the width of shift fork hook (sliding area with coupling sleeve) is within allowable specification below.

One-side wear One-side wear

One-side wear specification

Sliding width of new part

1st & 2nd

0.2 mm (0.008 in)

7.80 - 7.93 mm (0.3071 - 0.3122 in)

3rd & 4th

0.2 mm (0.008 in)

7.80 - 7.93 mm (0.3071 - 0.3122 in)

5th & reverse

0.2 mm (0.008 in)

7.80 - 7.93 mm (0.3071 - 0.3122 in)

Item Sliding width of new part SMT801D

MT-74

REPAIR FOR COMPONENT PARTS

RS5F70A Shift Control Components (Cont’d)

I

1st & 2nd fork rod

Check if shift check groove of fork rod or 5th & reverse check groove is worn, or has any other abnormalities.

5th & reverse fork rod

3rd & 4th fork rod

SMT692D

MT-75

NCMT0023

ASSEMBLY

RS5F70A

Clutch Housing

Clutch Housing

NCMT0023S01

1.

Hammer the striking rod oil seal into clutch housing as far as it will go. CAUTION: Do not reuse striking rod oil seal. Striking rod oil seal

SMT722D

2.

Hammer the differential oil seal into clutch housing until it becomes flush with clutch housing end face. CAUTION: Do not reuse differential oil seal.

Differential oil seal

SMT723D

3.

Hammer input shaft oil seal into clutch housing as far as it will go. CAUTION: Do not reuse input shaft oil seal.

Input shaft oil seal

SMT724D

4. Hammer the dust seal into clutch housing as far as it will go. CAUTION: Do not reuse dust seal.

Dust seal

SMT725D

5.

Install outer race of differential side bearing.

Differential side bearing outer race SMT726D

MT-76

ASSEMBLY

RS5F70A Clutch Housing (Cont’d)

6. Install new oil channel (mainshaft). CAUTION: Pay attention to installation direction of oil channel.

Oil channel

SMT727D

Notch on bearing

Transaxle case

7.

Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing.

8.

Install mainshaft bearing retainer, and tighten bolts with specified torque.

Mounting direction of bearing

Mainshaft front bearing SMT728D

Mainshaft bearing retainer 6.3 - 8.3 (0.64 - 0.85, 56 - 74)

N·m (kg-m, in-lb)

SMT729D

9.

Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever. CAUTION: I Before installing striking rod, wrap the end with a vinyl tape or the like to prevent oil seal from being damaged. I Do not reuse retaining pin. Striking lever

SMT667D

10. Hammer the welch plug (striking lever side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug. Drift Welch plug drift depth

Welch plug

0 - 0.5 mm (0 - 0.020 in) Welch plug SMT730D

MT-77

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

11. Install selector, selector shaft, and selector shaft pin into clutch housing.

Selector shaft pin Selector

Welch plug

Selector shaft

SMT731D

12. Hammer the welch plug (selector shaft side) with a generalpurpose drift [OD: 12 mm (0.47 in)]. CAUTION: Do not reuse welch plug.

Drift Welch plug drift depth

Welch plug

0 - 0.5 mm (0 - 0.020 in) Welch plug SMT732D

Reamer bolt (short) Reamer bolt (long)

Selector leaf spring Return spring

Bushing

Reverse gate

Return bearing

13. Install selector leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing. Then, tighten two reamer bolts with specified torque. CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.

Selector arm SMT733D

Steel ball

N·m (kg-m, ft-lb) 16 - 21 (1.6 - 2.1, 12 - 15)

SMT734D

14. Install oil pocket.

Oil pocket

SMT735D

MT-78

RS5F70A

ASSEMBLY

Clutch Housing (Cont’d)

15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing. CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.

SMT736D

1st & 2nd shift fork

16. Install 5th & reverse shift fork. 17. Install 1st & 2nd shift fork, bracket, and fork rod. 18. Install retaining pin for 1st & 2nd bracket. CAUTION: Do not reuse retaining pin. 19. Install two check balls.

1st & 2nd bracket Check balls SMT659D

5th & reverse shift fork 5th & reverse bracket

SMT657D

20. Install interlock pin into 5th & reverse fork rod. 21. Install reverse switch bracket, 5th & reverse bracket, and fork rod. 22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket. CAUTION: Do not reuse retaining pin. 23. Install 5th & reverse bracket stopper ring. CAUTION: Do not reuse stopper pin. 24. Install check ball and interlock plunger. 25. Install 3rd & 4th shift fork, bracket, and fork rod. 26. Install 3rd & 4th bracket retaining pin. CAUTION: Do not reuse retaining pin.

3rd & 4th shift fork 3rd & 4th bracket

SMT656D

27. Install 3rd & 4th shift fork stopper ring. CAUTION: Do not reuse stopper ring. 28. Install check ball, check pin, and check spring, and apply Three Bond TB1215, Loctite Part No. 51813 or equivalent onto check plug. Then, tighten it with specified torque. Tightening torque: Refer to MT-48.

Stopper ring

3rd & 4th shift fork .

3rd & 4th bracket

SMT655D

MT-79

ASSEMBLY

RS5F70A

Transaxle Case

Transaxle Case

Differential oil seal

Drift

NCMT0023S02

1.

Insert differential oil seal into differential case until it becomes flush with case end face.

2.

Install welch plug into transaxle case.

3.

Calculate dimension “N” (thickness of adjusting shim) using the following procedure to satisfy specification of end play for differential side bearing. End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in) Dimension “N” = (N1 − N2) + End play N : Thickness of adjusting shim N1: Distance between clutch housing case end face and mounting face of adjusting shim N2: Distance between differential side bearing and transaxle case Available differential side bearing adjusting shims: Refer to SDS, MT-92.

a.

Using dial gauge and scale, measure dimension “N1” between clutch housing case end face and mounting face of adjusting shim.

SMT737D

Welch plug drift depth Welch plug Welch plug 1.0 - 1.5 mm (0.039 - 0.059 in)

Outer race adjusting shim

SMT739D

Outer race

Transaxle case

SMT740D

Scale

SMT741D

MT-80

RS5F70A

ASSEMBLY

Transaxle Case (Cont’d) Scale

b.

c. Scale

Install outer race onto differential side bearing on final gear side. Holding lightly the outer race horizontally by hand, rotate final gear five times or more (for smooth movement of bearing roller). Using dial gauge and scale as shown in the figure, measure dimension “N2” between differential side bearing outer race and transaxle case end face.

SMT742D

4.

Install selected shim and bearing outer race.

5.

Measure turning torque of final drive assembly. Turning torque of final drive assembly (New bearing): 2.9 - 6.9 N⋅m (30 - 70 kg-cm, 26 - 61 in-lb) When old bearing is used again, turning torque will be slightly less than the above. Make sure torque is close to the specified range. Changes in turning torque of final drive assembly per revolution should be within 1.0 N⋅m (10 kg-cm, 8.7 in-lb) without binding.

Outer race SMT738D

I I I SMT600-D

6. Transaxle case Input shaft rear bearing

Input shaft rear bearing adjusting shim

Rear cover Dimension “O”

SMT743D

Calculate dimension “O” (thickness of adjusting shim) using the following procedure to satisfy specification of end play for input shaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension “O” = (O1 − O2) + End play O : Thickness of adjusting shim O1: Distance between transaxle case end face and mounting face of adjusting shim O2: Distance between clutch housing case end face and end face of input shaft rear bearing Available input shaft rear bearing adjusting shims: Refer to SDS, MT-91.

MT-81

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

a.

Using block gauge, scale, and dial gauge, measure dimension “O1” between transaxle case end face and mounting face of adjusting shim.

b.

Using gauge block, scale, and dial gauge as shown in the figure, measure dimension “O2” between clutch housing case end face and end face of input shaft rear bearing. Install selected input shaft rear bearing adjusting shim onto input shaft.

Scale Block gauge

SMT744D

Scale

7.

Block gauge

SMT745D

Oil gutter

8.

Install oil gutter into transaxle case.

9.

Install two magnets.

SMT650D

Magnets

SMT755D

10. Clean mating surfaces of clutch housing and transaxle case. Check for cracks and damage. Then, apply Three Bond TB1215, Loctite Part No. 51813 or equivalent.

SMT802D

MT-82

ASSEMBLY

RS5F70A Transaxle Case (Cont’d)

Clutch housing

Transaxle case

SMT649D

Reverse switch PNP switch

Filler plug

11. Install transaxle case onto clutch housing, and tighten mounting bolts with specified torque. Tightening torque: Refer to MT-48.

12. Apply Three Bond TB1215, Loctite Part No. 51813 or equivalent to threads of reverse switch, PNP switch, and drain plug, and install them. (Fill the case with oil before installation of filler plug.) 13. Install speedometer pinion assembly. CAUTION: Do not reuse O-ring.

Drain plug SMT648D

14. Install check springs and check balls. Apply sealant to the thread on the check plug, and install it. Check balls Check springs Check plugs 16 - 22 (1.6 -2.2, 12 -16) N·m (kg-m, ft-lb) SMT749D

Rear cover Mainshaft rear bearing adjusting shim Mainshaft rear bearing

Dimension “P”

SMT746D

15. Calculate thickness of adjusting shim using the following procedure to satisfy specification of end play for mainshaft rear bearing. End play: 0 - 0.06 mm (0 - 0.0024 in) Dimension “P” = (P1 − P2) + End play P : Thickness of adjusting shim P1: Distance between transaxle case end face and mainshaft rear bearing P2: Distance between adjusting shim end face of rear cover and transaxle mounting face Available mainshaft rear bearing adjusting shims: Refer to SDS, MT-92.

MT-83

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

a.

Using dial gauge as shown in the figure, measure dimension “P1” between transaxle case end face and mainshaft rear bearing.

b.

Using dial gauge as shown in the figure, measure dimension “P2” between adjusting shim mounting face of rear cover and transaxle mounting face.

Mainshaft rear bearing SMT747D

Rear cover

SMT748D

16. Using snap ring pliers as shown in the figure, install snap ring. CAUTION: Do not reuse snap ring. 17. Install selected mainshaft adjusting shim.

Flat-head screwdriver Mainshaft rear bearing snap ring SMT646D

Reverse idler gear rear thrust washer Reverse idler gear Reverse idler gear bearing

18. Install reverse idler gear, O-ring, thrust washers (front, rear), and bearing onto reverse idler shaft. 19. Install snap ring into transaxle case using snap ring pliers. CAUTION: I Do not reuse snap ring. I Do not reuse O-ring. I Before installation, apply gear oil to O-ring.

Reverse idler gear front thrust washer O-ring Reverse idler gear shaft

Feeler gauge

SMT753D

20. Using feeler gauge, measure the end play of snap ring, and select a snap ring suitable to satisfy the following specification. End play: 0.05 - 0.25 mm (0.0020 - 0.0098 in) Available snap ring: Refer to SDS, MT-90.

Snap ring

SMT754D

MT-84

ASSEMBLY

RS5F70A Transaxle Case (Cont’d)

Snap ring

Rear cover

Side cover

SMT644D

21. Install selected snap ring. CAUTION: Do not reuse snap ring. 22. Apply gear oil to rear cover O-ring, and install rear cover, side cover gasket, and side cover. Then tighten mounting bolts with specified torque. Tightening torque: Refer to MT-48. CAUTION: Do not reuse mounting bolts for rear cover and side cover.

MT-85

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications — RS5F32A and RS5F70A

General Specifications — RS5F32A and RS5F70A TRANSAXLE Engine

CD20T

Transaxle model

QG16DE

QG18DE

RS5F32A

Transaxle model code number

SR20DE

RS5F70A

2J624

8E069

7J006

Number of speeds

5

Synchromesh type

Warner

6J016

Shift pattern

NMT031

Gear ratio

Number of teeth

1st

3.3333

3.3333

2nd

1.9545

1.9545

3rd

1.2857

1.2857

4th

0.9268

0.9268

5th

0.7333

0.7556

Reverse

3.2143

3.2143

Input gear

Main gear

1st

15

15

2nd

22

22

3rd

28

28

4th

41

41

5th

45

45

Rev.

14

14

1st

50

50

2nd

43

43

3rd

36

36

4th

38

38

5th

33

34

Rev.

45

Reverse idler gear Oil capacity (Reference) Oil level

 (Imp pt) mm (in)

45

31

37

3.6 - 3.8 (6-3/8 - 6-3/4)

3.0 (5-1/4) 75.5 - 80.5 (2.972 - 3.169)

57 - 62 (2.244 - 2.441)

FINAL GEAR Engine

QG16DE

QG18DE/ SR20DE

CD20T

4.4375

4.1765

3.8888

Final gear/ Pinion

71/16

71/17

70/18

Side gear/ Pinion

16/10

14/10

14/10

Final gear ratio

Number of teeth

MT-86

56.5 - 61.0 (2.224 - 2.402)

RS5F32A

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment — RS5F32A

Inspection and Adjustment — RS5F32A GEAR END PLAY

AVAILABLE SNAP RINGS

Gear

Input shaft front bearing

End play mm (in)

1st main gear

0.18 - 0.31 (0.0071 - 0.0122)

2nd main gear

0.20 - 0.30 (0.0079 - 0.0118)

Thickness mm (in)

Part number

3rd main gear

0.20 - 0.30 (0.0079 - 0.0118)

1.27 (0.0500)

32204-M8004

4th main gear

0.20 - 0.30 (0.0079 - 0.0118)

1.33 (0.0524)

32204-M8005

5th input gear

0.18 - 0.31 (0.0071 - 0.0122)

1.39 (0.0547)

32204-M8006

1.45 (0.0571)

32204-M8007

Allowable clearance

CLEARANCE BETWEEN BAULK RING AND GEAR

0 - 0.1 mm (0 - 0.004 in)

Input shaft 5th synchronizer hub

1st, 4th, 5th baulk ring Unit: mm (in) Standard

Allowable clearance

0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in)

Part number

2.00 (0.0787)

32311-M8812

2.05 (0.0807)

32311-M8813

2.10 (0.0827)

32311-M8814

2.15 (0.0846)

32311-M8815

2.20 (0.0866)

32311-M8816

2.25 (0.0886)

32311-M8817

2.30 (0.0906)

32311-M8818

Wear limit

1st

0.95 - 1.45 (0.0374 - 0.0571)

4th

0.90 - 1.45 (0.0354 - 0.0571)

5th

0.90 - 1.50 (0.0354 - 0.0591)

0.7 (0.028)

2nd and 3rd baulk ring Outer baulk ring B

AVAILABLE C-RINGS Mainshaft C-ring

A

Allowable clearance

Inner baulk ring Synchronizer cone

0 - 0.1 mm (0 - 0.004 in)

Thickness mm (in)

Part number

4.45 (0.1752)

32348-50J00

4.52 (0.1780)

32348-50J01

4.59 (0.1807)

32348-50J02

4.66 (0.1835)

32348-50J03

4.73 (0.1862)

32348-50J04

4.80 (0.1890)

32348-50J05

4.87 (0.1917)

32348-50J06

4.94 (0.1945)

32348-50J07

NMT026

Dimension

Standard

A

0.7 - 0.9 (0.028 - 0.035)

B

0.6 - 1.1 (0.024 - 0.043)

Wear limit

0.2 (0.008)

AVAILABLE CHECK PLUGS Reverse check plug Reverse check turning torque (At striking rod)

4.9 - 7.4 N·m (50 - 75 kg-cm, 43 - 65 in-lb)

Length mm (in)

Part number

8.3 (0.327)

32188-M8001*

7.1 (0.280)

32188-M8002

7.7 (0.303)

32188-M8003

8.9 (0.350)

32188-M8004 * Standard check plug

MT-87

RS5F32A

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment — RS5F32A (Cont’d)

AVAILABLE SPACERS

AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM

Mainshaft bearing adjusting spacer

Bearing preload (Re-used bearing) Mainshaft rear bearing

Unit: mm (in) Mainshaft

Mainshaft adjusting spacing

Differential side bearing preload: T*

0.25 - 0.30 (0.0098 - 0.0118)

* Install shims which are “deflection of differential case” + “T” in thickness.

SMT693B

Turning torque (New bearing) Unit: N·m (kg-cm, in-lb)

230.15 - 230.25 mm (9.0610 - 9.0649 in)

Bearing distance: C

Final drive

2.9 - 6.9 (30 - 70, 26 - 61)

Thickness mm (in)

Part number

18.91 (0.7445)

32347-50J00

18.98 (0.7472)

32347-50J01

19.05 (0.7500)

32347-50J02

Thickness mm (in)

Part number

19.12 (0.7528)

32347-50J03

0.44 (0.0173)

38454-M8000

19.19 (0.7555)

32347-50J04

0.48 (0.0189)

38454-M8001

19.26 (0.7583)

32347-50J05

0.56 (0.0220)

38454-M8003

19.33 (0.7610)

32347-50J06

0.60 (0.0236)

38454-M8004

19.40 (0.7638)

32347-50J07

0.64 (0.0252)

38454-M8005

19.47 (0.7665)

32347-50J08

0.68 (0.0268)

38454-M8006

0.72 (0.0283)

38454-M8007

AVAILABLE WASHERS

0.76 (0.0299)

38454-M8008

Differential side gear thrust washer

0.80 (0.0315)

38454-M8009

0.84 (0.0331)

38454-M8010

0.88 (0.0346)

38454-M8011

Allowable clearance between side gear and differential case with washer

F32A

Differential side bearing adjusting shims

0.1 - 0.2 mm (0.004 - 0.008 in)

Thickness mm (in)

Part number

0.75 - 0.80 (0.0295 - 0.0315)

38424-D2111

0.80 - 0.85 (0.0315 - 0.0335)

38424-D2112

0.85 - 0.90 (0.0335 - 0.0354)

38424-D2113

0.90 - 0.95 (0.0354 - 0.0374)

38424-D2114

0.95 - 1.00 (0.0374 - 0.0394)

38424-D2115

MT-88

SERVICE DATA AND SPECIFICATIONS (SDS)

RS5F32A

Inspection and Adjustment — RS5F32A (Cont’d)

INPUT SHAFT BRAKING MECHANISM

1st & 2nd shifter Striking lever

Control bracket fitting surface

MAINSHAFT END PLAY Mainshaft end play (Clearance between end of case cover and mainshaft rear bearing outer race)

Reverse brake cam

0 - 0.1 mm (0 - 0.004 in)

SMT735B

Maximum height “H” between the control bracket fitting surface and 1-2 shifter mm (in)

67.16 - 67.64 (2.6441 - 2.6630)

Case cover

Reverse brake cam Striking lever

T

SMT760B

Thickness “T” mm (in)

Part No.

10.78 (0.4244)

32131-50J00

10.83 (0.4264)

32131-50J01

10.88 (0.4283)

32131-50J02

10.93 (0.4303)

32131-50J03

SMT736B

Clearance “C” between reverse brake cam and striking lever mm (in)

0.05 - 0.125 (0.0020 - 0.0049)

MT-89

10.98 (0.4323)

32131-50J04

11.03 (0.4343)

32131-50J05

RS5F70A

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment — RS5F70A

Inspection and Adjustment — RS5F70A GEAR END PLAY

NCMT0025

Unit: mm (in)

Gear

AVAILABLE SNAP RINGS Snap Ring

NCMT0028 NCMT0028S01

End play Allowable clearance

1st main gear 2nd main gear

0.05 - 0.25 mm (0.0020 - 0.0098 in)

Thickness

Part number*

1.45 mm (0.0571 in)

32204-6J000

Reverse main gear

1.55 mm (0.0610 in)

32204-6J001

3rd input gear

1.65 mm (0.0650 in)

32204-6J002

1.75 mm (0.0689 in)

32204-6J003

1.85 mm (0.0728 in)

32204-6J004

5th main gear

0.18 - 0.31 (0.0071 - 0.0122)

4th input gear

0.17 - 0.44 (0.0067 - 0.0173)

CLEARANCE BETWEEN BAULK RING AND GEAR NCMT0026 3rd, 4th, 5th, Reverse Baulk Ring NCMT0026S01 Unit: mm (in) Standard

Wear limit

*: Always check with the parts department for the latest information.

AVAILABLE C-RINGS 4th Input Gear C-ring

3rd

Allowable clearance

4th

0.90 - 1.45 (0.0354 - 0.0571) 0.7 (0.028)

5th Reverse

0.9 - 1.35 (0.0354 - 0.0531)

1st and 2nd Baulk Ring

NCMT0026S02

Unit: mm (in)

NCMT0029 NCMT0029S01

0 - 0.06 mm (0 - 0.0024 in)

Thickness

Part number*

3.00 mm (0.1181 in)

32205-6J000

3.03 mm (0.1193 in)

32205-6J001

3.06 mm (0.1205 in)

32205-6J002

3.09 mm (0.1217 in)

32205-6J003

Outer baulk ring

5th Input Gear Rear C-ring Allowable clearance

Inner baulk ring

NCMT0029S02

0 - 0.06 mm (0 - 0.0024 in)

Thickness

Part number*

2.59 mm (0.1020 in)

32205-6J005

2.62 mm (0.1031 in)

32205-6J006

2.65 mm (0.1043 in)

32205-6J007

2.68 mm (0.1055 in)

32205-6J008

2.71 mm (0.1067 in)

32205-6J009

2.74 mm (0.1079 in)

32205-6J010

Synchronizer cone SMT757C

Dimension

Standard

A

0.6 - 0.8 (0.024 0.031)

B

0.6 - 1.1 (0.024 0.043)

Wear limit

0.2 (0.008)

MT-90

RS5F70A

SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment — RS5F70A (Cont’d)

Mainshaft C-ring Allowable clearance

NCMT0029S03

0 - 0.06 mm (0 - 0.0024 in)

AVAILABLE ADJUSTING SHIMS NCMT0037 Input Shaft Rear Bearing Adjusting Shim NCMT0037S01 Allowable clearance

0 - 0.06 mm (0 - 0.0024 in)

Thickness

Part number*

3.48 mm (0.1370 in)

32348-6J000

Thickness

Part number*

3.51 mm (0.1382 in)

32348-6J001

0.74 mm (0.0291 in)

32225-6J003

3.54 mm (0.1394 in)

32348-6J002

0.78 mm (0.0307 in)

32225-6J004

3.57 mm (0.1406 in)

32348-6J003

0.82 mm (0.0323 in)

32225-6J005

3.60 mm (0.1417 in)

32348-6J004

0.86 mm (0.0339 in)

32225-6J006

3.63 mm (0.1429 in)

32348-6J005

0.90 mm (0.0354 in)

32225-6J007

3.66 mm (0.1441 in)

32348-6J006

0.94 mm (0.0370 in)

32225-6J008

3.69 mm (0.1453 in)

32348-6J007

0.98 mm (0.0386 in)

32225-6J009

3.72 mm (0.1465 in)

32348-6J008

1.02 mm (0.0402 in)

32225-6J010

3.75 mm (0.1476 in)

32348-6J009

1.06 mm (0.0417 in)

32225-6J011

3.78 mm (0.1488 in)

32348-6J010

1.10 mm (0.0433 in)

32225-6J012

3.81 mm (0.1500 in)

32348-6J011

1.14 mm (0.0449 in)

32225-6J013

3.84 mm (0.1512 in)

32348-6J012

1.18 mm (0.0465 in)

32225-6J014

3.87 mm (0.1524 in)

32348-6J013

1.22 mm (0.0480 in)

32225-6J015

3.90 mm (0.1535 in)

32348-6J014

1.26 mm (0.0496 in)

32225-6J016

3.93 mm (0.1547 in)

32348-6J015

1.30 mm (0.0512 in)

32225-6J017

3.96 mm (0.1559 in)

32348-6J016

1.34 mm (0.0528 in)

32225-6J018

1.38 mm (0.0543 in)

32225-6J019

1.42 mm (0.0559 in)

32225-6J020

1.46 mm (0.0575 in)

32225-6J021

1.50 mm (0.0591 in)

32225-6J022

1.54 mm (0.0606 in)

32225-6J023

1.58 mm (0.0622 in)

32225-6J024

1.62 mm (0.0638 in)

32225-6J060

1.66 mm (0.0654 in)

32225-6J061

*: Always check with the parts department for the latest information.

Mainshaft Adjusting Shim Standard length “L”

NCMT0037S02

151.35 - 151.45 mm (5.9586 5.9626 in)

Thickness

Part number*

0.48 mm (0.0189 in)

32238-6J000

0.56 mm (0.0220 in)

32238-6J001

0.64 mm (0.0252 in)

32238-6J002

0.72 mm (0.0283 in)

32238-6J003

0.80 mm (0.0315 in)

32238-6J004

0.88 mm (0.0346 in)

32238-6J005

*: Always check with the parts department for the latest information.

MT-91

SERVICE DATA AND SPECIFICATIONS (SDS)

RS5F70A

Inspection and Adjustment — RS5F70A (Cont’d)

Mainshaft Rear Bearing Adjusting Shim NCMT0037S03

AVAILABLE WASHERS NCMT0031 Differential Side Gear Thrust Washer NCMT0031S01

Thickness

Part number*

2.99 mm (0.1177 in)

32238-6J010

3.03 mm (0.1193 in)

32238-6J011

3.07 mm (0.1209 in)

32238-6J012

Thickness mm (in)

Part number*

3.11 mm (0.1224 in)

32238-6J013

0.75 - 0.80 (0.0295 - 0.0315)

38424-D2111

3.15 mm (0.1240 in)

32238-6J014

0.80 - 0.85 (0.0315 - 0.0335)

38424-D2112

3.19 mm (0.1256 in)

32238-6J015

0.85 - 0.90 (0.0335 - 0.0354)

38424-D2113

3.23 mm (0.1272 in)

32238-6J016

0.90 - 0.95 (0.0354 - 0.0374)

38424-D2114

3.27 mm (0.1287 in)

32238-6J017

0.95 - 1.00 (0.0374 - 0.0394)

38424-D2115

3.31 mm (0.1303 in)

32238-6J018

3.35 mm (0.1319 in)

32238-6J019

3.39 mm (0.1335 in)

32238-6J020

3.43 mm (0.1350 in)

32238-6J021

3.47 mm (0.1366 in)

32238-6J022

3.51 mm (0.1382 in)

32238-6J023

AVAILABLE THRUST WASHER Mainshaft Thrust Washer

Allowable clearance between side gear and differential case with washer

0.1 - 0.2 mm (0.004 - 0.008 in)

AVAILABLE SHIMS — DIFFERENTIAL SIDE BEARING PRELOAD AND ADJUSTING SHIM NCMT0032 Bearing Preload NCMT0032S01 Unit: mm (in) Differential side bearing preload: T*

NCMT0038

0.15 - 0.21 (0.0059 - 0.0083)

* Install shims which are “deflection of differential case” + “T” in thickness.

NCMT0038S01

Differential Side Bearing Adjusting Shims NCMT0032S03

244.20 - 244.30 mm (9.6142 - 9.6181 in)

Thickness mm (in)

Part number*

0.44 (0.0173)

38454-M8000

0.48 (0.0189)

38454-M8001

0.52 (0.0205)

38454-M8002

0.56 (0.0220)

38454-M8003

0.60 (0.0236)

38454-M8004

0.64 (0.0252)

38454-M8005

SMT843D

0.68 (0.0268)

38454-M8006

244.20 - 244.30 mm (9.6142 9.6181 in)

0.72 (0.0283)

38454-M8007

Thickness

Part number*

0.76 (0.0299)

38454-M8008

6.04 mm (0.2378 in)

32246-6J000

0.80 (0.0315)

38454-M8009

6.12 mm (0.2409 in)

32246-6J001

0.84 (0.0331)

38454-M8010

6.20 mm (0.2441 in)

32246-6J002

0.88 (0.0346)

38454-M8011

6.28 mm (0.2472 in)

32246-6J003

6.36 mm (0.2504 in)

32246-6J004

Standard length “M”

*: Always check with the parts department for the latest information.

*: Always check with the parts department for the latest information.

MT-92

AUTOMATIC TRANSAXLE SECTION

AT

(H⋅CVT)

CONTENTS TROUBLE DIAGNOSIS - INDEX ....................................3 Alphabetical & P No. Index for DTC ...........................3 PRECAUTIONS ...............................................................5 Precautions for Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ ......................................................5 Precautions for On Board Diagnostic (OBD) System of CVT and Engine.........................................5 Precautions ..................................................................5 Service Notice or Precautions .....................................6 Wiring Diagrams and Trouble Diagnosis.....................7 PREPARATION ...............................................................8 Special Service Tools ..................................................8 OVERALL SYSTEM ........................................................9 CVT Electrical Parts Location......................................9 Circuit Diagram ..........................................................10 Cross-sectional View - RE0F06A ..............................11 Control System ..........................................................12 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................15 Introduction ................................................................15 OBD Function for CVT System .................................15 OBD Diagnostic Trouble Code (DTC) .......................15 Malfunction Indicator (MI) ..........................................18 CONSULT-II ...............................................................18 TROUBLE DIAGNOSIS - INTRODUCTION..................29 Introduction ................................................................29 Work Flow..................................................................32 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........34 CVT Fluid Check .......................................................34 Stall Test ....................................................................34 Line Pressure Test.....................................................35 Road Test...................................................................36 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................41 TCM Terminals and Reference Value........................41

TROUBLE DIAGNOSIS FOR POWER SUPPLY..........45 Wiring Diagram - CVT - MAIN...................................45 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH .........................................................................48 Description .................................................................48 Wiring Diagram - AT - PNP/SW.................................50 Diagnostic Procedure ................................................51 Component Inspection...............................................53 DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT .........................................................................54 Description .................................................................54 Wiring Diagram - AT - FTS ........................................56 Diagnostic Procedure ................................................57 DTC P0715 PRIMARY SPEED SENSOR .....................59 Description .................................................................59 Wiring Diagram - AT - VSSA/T ..................................60 Diagnostic Procedure ................................................61 Component Inspection...............................................61 DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) ................................62 Description .................................................................62 Wiring Diagram - AT - VSSA/T ..................................64 Diagnostic Procedure ................................................65 Component Inspection...............................................65 DTC P0725 ENGINE SPEED SIGNAL .........................66 Description .................................................................66 Wiring Diagram - AT - ENGSS ..................................67 Diagnostic Procedure ................................................68 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE........................................................69 Description .................................................................69 Wiring Diagram - AT - TCV........................................71 Diagnostic Procedure ................................................72 Component Inspection...............................................73 DTC P0745 LINE PRESSURE SOLENOID VALVE .....74 Description .................................................................74

AT

CONTENTS Wiring Diagram - AT - LPSV......................................76 Diagnostic Procedure ................................................77 Component Inspection...............................................78 DTC P1705 THROTTLE POSITION SENSOR .............79 Description .................................................................79 Wiring Diagram - AT - TPS........................................81 Diagnostic Procedure ................................................82 Component Inspection...............................................85 DTC P1777 STEP MOTOR - CIRCUIT .........................86 Description .................................................................86 Wiring Diagram - AT - STM .......................................88 Diagnostic Procedure ................................................89 Component Inspection...............................................90 DTC P1778 STEP MOTOR - FUNCTION .....................91 Description .................................................................91 Diagnostic Procedure ................................................93 DTC P1791 CVT FLUID PRESSURE SENSOR ...........94 Description .................................................................94 Wiring Diagram - AT - FPS........................................96 Diagnostic Procedure ................................................97 Component Inspection...............................................98 CVT SAFE FUNCTION..................................................99 Description .................................................................99 Diagnostic Procedure ..............................................100 CONTROL UNIT (RAM), CONTROL UNIT (ROM).....101 Description ...............................................................101

(Cont’d)

Diagnostic Procedure ..............................................102 CONTROL UNIT (EEPROM) .......................................103 Description ...............................................................103 Diagnostic Procedure ..............................................104 TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS...........................................................................105 PNP Switch, Stop Lamp Switch and Throttle Position Switch ........................................................105 Wiring Diagram - AT - NONDTC .............................110 ON-VEHICLE SERVICE ..............................................114 Control Cable Adjustment........................................114 Park/Neutral Position (PNP) Switch Adjustment .....114 Differential Side Oil Seal Replacement ...................114 REMOVAL AND INSTALLATION ...............................116 Removal...................................................................116 Inspection.................................................................116 Installation................................................................117 Air Breather Hose ....................................................118 CVT Fluid Cooler (Hyper CVT-M6) .........................118 Components.............................................................119 SERVICE DATA AND SPECIFICATIONS (SDS) .......120 General Specifications.............................................120 Stall Revolution........................................................120 Line Pressure...........................................................120 Removal and Installation .........................................120

AT-2

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC

Alphabetical & P No. Index for DTC

NCAT0001

ALPHABETICAL INDEX FOR DTC

NCAT0001S01

DTC Items (CONSULT-II screen terms)

CONSULT-II GST*2

Reference page

ECM*1

ATF TEMP SEN/CIRC

0710

P0710

AT-54

ENG SPEED SIG

0725

P0725

AT-66

LINE PRESSURE SEN

1791

P1791

AT-94

L/PRESS SOL/CIRC

0745

P0745

AT-74

PNP SW/CIRC

0705

P0705

AT-48

PRI SPEED SIG/CIRC

0715

P0715

AT-59

STEP MOTOR/CIRC

1777

P1777

AT-86

STEP MOTOR/FNCTN

1778

P1778

AT-91

TP SEN/CIRC A/T*3

1705

P1705

AT-79

TCC SOLENOID/CIRC

0740

P0740

AT-69

VEH SPD SEN/CIR A/T

0720

P0720

AT-62

*1: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. *2: These numbers are prescribed by ISO15031-6. *3: When the fail-safe operation occurs, the MI illuminates.

AT-3

TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC (Cont’d)

P NO. INDEX FOR DTC

=NCAT0001S02

DTC Items (CONSULT-II screen terms)

Reference page

CONSULT-II GST*2

ECM*1

P0705

0705

PNP SW/CIRC

AT-48

P0710

0710

ATF TEMP SEN/CIRC

AT-54

P0715

0715

PRI SPEED SIG/CIRC

AT-59

P0720

0720

VEH SPD SEN/CIR AT

AT-62

P0725

0725

ENG SPEED SIG

AT-66

P0740

0740

TCC SOLENOID/CIRC

AT-69

P0745

0745

L/PRESS SOL/CIRC

AT-74

P1705

1705

TP SEN/CIRC A/T*3

AT-79

P1777

1777

STEP MOTOR/CIRC

AT-86

P1778

1778

STEP MOTOR/FNCTN

AT-91

P1791

1791

LINE PRESSURE SEN

AT-94

*1: In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. *2: These numbers are prescribed by ISO15031-6. *3: When the fail-safe operation occurs, the MI illuminates.

AT-4

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

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

NCAT0002

The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).

Precautions for On Board Diagnostic (OBD) System of CVT and Engine

NCAT0198

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: I Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. I Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) I Be sure to route and secure the harnesses properly after work. Interference of the harness with a bracket, etc. may cause the MI to light up due to a short circuit. I Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc. I Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and ECM before returning the vehicle to the customer.

Precautions I

NCAT0003

Before connecting or disconnecting the TCM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM even if ignition switch is turned off.

SEF289H

AT-5

PRECAUTIONS Precautions (Cont’d)

I

When connecting or disconnecting pin connectors into or from TCM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on TCM pin terminal, when connecting pin connectors.

I

Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. (See page AT-41.)

I

After performing each TROUBLE DIAGNOSIS, perform “DTC (Diagnostic Trouble Code) CONFIRMATION PROCEDURE”. The DTC should not be displayed in the “DTC CONFIRMATION PROCEDURE” if the repair is completed.

I

It is very important to perform functional tests whenever they are indicated. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. When the CVT drain plug is removed, only some of the fluid is drained. Old CVT fluid will remain in torque converter and CVT fluid cooling system. Always follow the procedures under “Changing CVT Fluid” in the MA section when changing CVT fluid.

SEF291H

Perform TCM input/output signal inspection before replacement.

MEF040DA

SAT652J

I I

Service Notice or Precautions FAIL-SAFE

NCAT0004 NCAT0004S01

The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major electrical input/output device circuit is damaged. Under Fail-Safe, the vehicle always runs even with a shift lever position of “L” or “D”. The customer may complain of sluggish or poor acceleration. When the ignition key is turned “ON” following Fail-Safe operation, CVT or SPORT indicator lamp blinks for about 8 seconds. [For “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”, refer to AT-25.] Fail-Safe may occur without electrical circuit damage if the vehicle is driven under extreme conditions (such as excessive wheel spin followed by sudden braking). To recover normal shift pattern, turn the ignition key “OFF” for 5 seconds, then “ON”.

AT-6

PRECAUTIONS Service Notice or Precautions (Cont’d)

The blinking of the CVT or SPORT indicator lamp for about 8 seconds will appear only once and be cleared. The customer may resume normal driving conditions. Always follow the “WORK FLOW” (Refer to AT-32). The SELF-DIAGNOSIS results will be as follows: The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor. During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.

OBD SELF-DIAGNOSIS

NCAT0004S04

I

CVT self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through the blinking pattern of the CVT or SPORT indicator. Refer to the table on AT-19 for the indicator used to display each self-diagnostic result. I The self-diagnostic results indicated by the MI are automatically stored in both the ECM and TCM memories. Always perform the procedure “HOW TO ERASE DTC” on AT-16 to complete the repair and avoid unnecessary blinking of the MI. For details of OBD, refer to EC section (“ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). I Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL section, “Description”, “HARNESS CONNECTOR”.

Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the followings: I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section When you perform trouble diagnosis, refer to the followings: I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section

AT-7

NCAT0005

PREPARATION Special Service Tools

Special Service Tools Tool number Tool name ST2505S001 Oil pressure gauge set 1 ST25051001 Oil pressure gauge 2 ST25052000 Hose 3 ST25053000 Joint pipe 4 ST25054000 Adapter 5 ST25055000 Adapter

NCAT0006

Description Measuring line pressure and governor pressure

NT097

KV31103000 Drift

Installing differential side oil seal (Use with ST35325000) a: 59 mm (2.32 in) dia. b: 49 mm (1.93 in) dia. NT105

ST35325000 Drift

Installing differential side oil seal (Use with KV31103000) a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: M12 x 1.5P

NT417

AT-8

OVERALL SYSTEM CVT Electrical Parts Location

CVT Electrical Parts Location

Steering column

NCAT0008

Throttle position sensor and throttle position switch

Indicator C/U

Front

TCM

SPORT indicator lamp

CVT indicator lamp

Secondary speed sensor PNP switch Control valve connector

SPORT mode switch

Dropping resistor

Inside control valve Fluid temperature sensor Fluid pressure sensor Lock-up solenoid Line pressure solenoid Step motor Manual mode switch

Primary speed sensor

SAT671J

AT-9

OVERALL SYSTEM Circuit Diagram

Circuit Diagram

NCAT0009

YAT250

AT-10

OVERALL SYSTEM Cross-sectional View — RE0F06A

Cross-sectional View — RE0F06A

NCAT0011

Converter housing Reverse brake

Primary pulley

Planet carrier

Oil pump

Forward clutch

Torque converter

Steel belt

Sun gear Input shaft Side cover

Internal gear

Parking gear Output gear Taper roller bearing

Reduction gear

Idler gear

Speedometer drive gear Secondary pulley

Differential case Final gear

SAT668J

AT-11

OVERALL SYSTEM Control System

Control System

=NCAT0014

OUTLINE

NCAT0014S01

The CVT senses vehicle operating conditions through various sensors. It always controls the optimum shift position and reduces shifting and lock-up shocks. SENSORS

TCM

PNP switch Throttle position sensor Closed throttle position switch Wide open throttle position switch Engine speed signal CVT fluid temperature sensor CVT fluid pressure sensor Primary speed sensor Secondary speed sensor Stop lamp switch Sport mode switch (Hyper CVT only) Indicator control unit (Hyper CVT M6 only) ABS control unit

Shift control Line pressure control Lock-up control Fail-safe control Self-diagnosis CONSULT-II communication line control Duet-EU control On board diagnosis

E

AT-12

ACTUATORS

E

Step motor CVT indicator (warning) lamp (Hyper CVT M6 only) Torque converter clutch solenoid valve Line pressure solenoid valve SPORT indicator lamp (Hyper CVT only)

OVERALL SYSTEM Control System (Cont’d)

CONTROL SYSTEM

NCAT0014S02

Transaxle

Wheel

Differential gear

Belt and Pulley

Final gear

Forward and reverse change

Torque converter

Engine

Oil pump

Parking system Oil pressure control

Control device

Electrical control

Sport mode SW or manual mode SW Control valve

Engine speed sensor Primary pulley speed and secondary pulley speed sensor

[Hyper CVT-M6]

Position indicator

Indicator C/U

Throttle opening sensor

CVT indicator (warning) lamp or SPORT indicator lamp

TCM

ECM

Mechanical system Oil system Electrical system

ABS C/U Stop lamp SW

PNP switch

NAT310

AT-13

OVERALL SYSTEM Control System (Cont’d)

TCM FUNCTION

=NCAT0014S03

The function of the TCM is to: I Receive input signals sent from various switches and sensors. I Determine required line pressure, shifting point and lock-up operation. I Send required output signals to the step motor and the respective solenoids.

INPUT/OUTPUT SIGNAL OF TCM

NCAT0014S04

Sensors and actuators

Input

Output

Function

PNP switch

Detects select lever position and sends a signal to TCM.

Throttle position sensor

Detects throttle valve position and sends a signal to TCM.

Closed throttle position switch

Detects throttle valve’s fully-closed position and sends a signal to TCM.

Wide open throttle position switch

Detects a throttle valve position of greater than 1/2 of full throttle and sends a signal to TCM.

Engine speed signal

From ECM.

CVT fluid temperature sensor

Detects transmission fluid temperature and sends a signal to TCM.

CVT fluid pressure sensor

Detects transmission fluid pressure and sends a signal to TCM.

Primary speed sensor

Detects primary pulley rpm and sends a signal to TCM.

Secondary speed sensor

Detects secondary pulley rpm and sends a signal to TCM.

Stop lamp switch

Sends a signal to the TCM relaying the operation condition of the brake pedal.

Sport mode switch

Sends a signal to the TCM relaying the operation condition of the sport mode switch.

Indicator control unit*1

Sends a signal to the TCM operation condition of the manual mode switch in control device.

ABS control unit

Sends a signal to the TCM operation condition of the ABS.

Step motor

Regulates pulley position in relation to a signal sent from TCM.

Line pressure solenoid valve

Regulates (or decreases) line pressure suited to driving conditions in relation to a signal sent from TCM.

Torque converter clutch solenoid valve

Regulates (or decreases) lock-up pressure suited to driving conditions in relation to a signal sent from TCM.

CVT indicator (warning) lamp*2

Shows TCM faults, when CVT control components malfunction.

SPORT indicator lamp*3

Shows the operation condition of the SPORT mode switch. *3

Indicator control unit *1

Receives the information of gear position on manual mode from TCM, and sends a signal to indicator.

*1: Hyper CVT M6 models only *2: Hyper CVT M6 models *3: Hyper CVT models

AT-14

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction

Introduction

NCAT0017

The CVT system has two self-diagnostic systems. The first is the emission-related on board diagnostic system (OBD) performed by the TCM in combination with the ECM. The malfunction is indicated by the MI (malfunction indicator) and is stored as a DTC in the ECM memory but not the TCM memory. The second is the TCM original self-diagnosis indicated by the CVT indicator (warning) lamp or SPORT indicator lamp. The malfunction is stored in the TCM memory. The detected items are overlapped with OBD selfdiagnostic items. For detail, refer to AT-26.

OBD Function for CVT System

NCAT0018

The ECM provides emission-related on board diagnostic (OBD) functions for the CVT system. One function is to receive a signal from the TCM used with OBD-related parts of the CVT system. The signal is sent to the ECM when a malfunction occurs in the corresponding OBD-related part. The other function is to indicate a diagnostic result by means of the MI (malfunction indicator) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements. The MI automatically illuminates in Two Trip Detection Logic when a malfunction is sensed in relation to CVT system parts.

OBD Diagnostic Trouble Code (DTC) HOW TO READ DTC AND 1ST TRIP DTC

NCAT0020 NCAT0020S01

DTC and 1st trip DTC can be read by the following methods. 1. ( No Tools) The number of blinks of the malfunction indicator in the Diagnostic Test Mode II (Self-Diagnostic Results) Examples: 0705, 0710, 0715, 0720, etc. For details, refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”]. These DTCs are controlled by NISSAN. GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710, 2. ( with CONSULT-II or P0720, P0725, etc. These DTCs are prescribed by ISO15031-6. (CONSULT-II also displays the malfunctioning component or system.) I 1st trip DTC No. is the same as DTC No. I Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. However, in case of the Mode II and GST they do not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. CONSULT-II can identify them as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC is shown at left. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode for “ENGINE” with CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC.

SAT651J

If the DTC is being detected currently, the time data will be “0”.

AT-15

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)

SAT581J

If a 1st trip DTC is stored in the ECM, the time data will be “1t”.

SAT582J

Freeze Frame Data and 1st Trip Freeze Frame Data

NCAT0020S0101

The ECM has a memory function, which stores the driving condition such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed and vehicle speed at the moment the ECM detects a malfunction. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data, and the data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For detail, refer to EC section (“CONSULT-II”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). Only one set of freeze frame data (either 1st trip freeze frame data of freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1

Items Freeze frame data

2 3

Misfire — DTC: P0300 - P0306 (0300 - 0306) Fuel Injection System Function — DTC: P0171 (0171), P0172 (0172), P0174 (0174), P0175 (0175) Except the above items (Includes CVT related items)

1st trip freeze frame data

Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased.

HOW TO ERASE DTC

NCAT0020S02

The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as described following. I If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours. I When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM.

AT-16

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)

The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC related to OBD. For details, refer to EC section (“Emission-related Diagnostic Information”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”). I Diagnostic trouble codes (DTC) I 1st trip diagnostic trouble codes (1st trip DTC) I Freeze frame data I 1st trip freeze frame data I System readiness test (SRT) codes I Test values I Distance traveled while MI is activated I Others

HOW TO ERASE DTC (WITH CONSULT-II)

NCAT0020S03

I If a DTC is displayed for both ECM and TCM, it needs to be erased for both ECM and TCM. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Turn CONSULT-II “ON” and touch “CVT”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the TCM will be erased.) Then touch “BACK” twice. 5. Touch “ENGINE”. 6. Touch “SELF-DIAG RESULTS”. 7. Touch “ERASE”. (The DTC in the ECM will be erased.) How to erase DTC (With CONSULT-II) 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again.

.

2. Turn CONSULT-II “ON”, and touch “CVT”.

3. Turn “SELF DIAGNOSIS”.

4. Touch “ERASE”. (The DTC in the TCM will be erased.) Touch “BACK”

Touch “BACK”

.

5. Touch “ENGINE”.

6. Touch “SELF DIAGNOSIS”.

7. Touch “ERASE”. (The DTC in the ECM will be erased.) SAT681J

AT-17

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD Diagnostic Trouble Code (DTC) (Cont’d)

HOW TO ERASE DTC (WITH GST)

NCAT0020S04

1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Perform “OBD SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-25. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC section “Generic Scan Tool (GST)”.

HOW TO ERASE DTC (NO TOOLS)

NCAT0020S05

1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-25. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 3. Change the diagnostic test mode from Mode II to Mode I by turning the mode selector on the ECM. Refer to EC section “HOW TO SWITCH DIAGNOSTIC TEST MODES”.

Malfunction Indicator (MI) 1. I

2. SAT652J

NCAT0021

The malfunction indicator will light up when the ignition switch is turned ON without the engine running. This is for checking the lamp. If the malfunction indicator does not light up, refer to EL section (“Warning Lamps/System Description”, “WARNING LAMPS AND CHIME”). (Or see MI & Data Link Connectors in EC section.) When the engine is started, the malfunction indicator should go off. If the lamp remains on, the on board diagnostic system has detected an emission-related (OBD) malfunction. For detail, refer to EC section (“ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”).

CONSULT-II

NCAT0022

After performing “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)” (AT-19), place check marks for results on the “DIAGNOSTIC WORKSHEET”, AT-31. Reference pages are provided following the items. NOTICE: I Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II unit.

AT-18

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)

NCAT0022S02

1.

Turn on CONSULT-II and touch “ENGINE” for OBD detected items or touch “CVT” for TCM self-diagnosis. If CVT is not displayed, check TCM power supply and ground circuit. Refer to AT-41. If result is NG, refer to EL section (“POWER SUPPLY ROUTING”).

2.

Touch “SELF DIAGNOSIS”. Display shows malfunction experienced since the last erasing operation. CONSULT-II performs REAL-TIME SELF-DIAGNOSIS. Also, any malfunction detected while in this mode will be displayed at real time.

SAT651J

SAT584J

SELF-DIAGNOSTIC RESULT TEST MODE

NCAT0022S03

TCM self-diagnosis

OBD (DTC)

Available by CVT or SPORT indicator lamp “CVT” on CONSULT-II

Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST

—

P0705

I TCM does not receive the proper voltage signal from the sensor.

X

P0715

I TCM does not receive the proper voltage signal from the sensor.

X

P0720

X

P0740

X

P0745

X

P1705

Detected items (Screen terms for CONSULT-II, “SELF DIAGNOSIS” test mode) Malfunction is detected when ...

“CVT”

“ENGINE”

PNP switch circuit PNP SW/CIRCUIT

PNP SW/CIRC

Primary speed sensor I/P PULLY SPD SIG

PRI SPEED SIG/ CIRC

Secondary speed sensor VEHICLE SPEED SIG

VEH SPD SEN/CIR A/T

T/C clutch solenoid valve T/C CLUTCH SOL/V

TCC SOLENOID/ CIRC

Line pressure solenoid valve LINE PRESSURE S/V

L/PRESS SOL/ CIRC

Throttle position sensor, Throttle position switch THROTTLE POSI SEN

I TCM does not receive the correct voltage signal (based on the gear position) from the switch.

I TCM detects an improper voltage drop when it tries to operate the solenoid valve. I TCM detects an improper voltage drop when it tries to operate the solenoid valve. I TCM receives an excessively low or high voltage from the sensor.

TP SEN/CIRC A/T

AT-19

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis

OBD (DTC)

Available by CVT or SPORT indicator lamp “CVT” on CONSULT-II

Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST

I TCM does not receive the proper voltage signal from the ECM.

X

P0725

I TCM receives an excessively low or high voltage from the sensor.

X

P0710

I Not proper voltage change of the TCM terminal when operating step motor.

X

P1777

I Step motor is not operating according to the TCM.

X

P1778

I TCM receives an excessively low or high voltage from the sensor.

X

P1791

X

—

I TCM memory (RAM) is malfunctioning.

—

—

I TCM memory (ROM) is malfunctioning.

—

—

I TCM memory (EEP ROM) is malfunctioning.

—

—

X

—

X

X

Detected items (Screen terms for CONSULT-II, “SELF DIAGNOSIS” test mode) Malfunction is detected when ...

“CVT”

“ENGINE”

Engine speed signal ENGINE SPEED SIG CVT fluid temperature sensor BATT/FLUID TEMP SEN

ATF TEMP SEN/ CIRC

Stepping motor circuit STEP MOTOR

STEP MOTOR/ CIRC

Stepping motor function —

STEP MOTOR/ FNCTN

CVT fluid pressure sensor LINE PRESSURE SEN

LINE PRESS SEN

I TCM is malfunctioning.

CVT SAFE FUNCTION CVT SAFE FUNCTION

—

TCM (RAM) CONTROL UNIT (RAM)

—

TCM (ROM) CONTROL UNIT (ROM)

—

TCM (EEP ROM) CONT UNIT (EEP ROM)

—

Initial start *INITIAL START*

—

No failure (NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER TESTING MAY BE REQUIRED**)

I This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen.) I No failure has been detected.

X: Applicable —: Not applicable *1: These malfunctions cannot be displayed by MI if another malfunction is assigned to MI. *2: Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].

AT-20

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

DATA MONITOR MODE (CVT)

NCAT0022S04

Monitor item Item

Display

Vehicle speed sensor VHCL SPEED (Secondary speed sensor) SE [km/h] or [mph]

Throttle position sensor

CVT fluid temperature sensor

THRTL POS SEN [V] FLUID TEMP SE [V]

Battery voltage

BATTERY VOLT [V]

Engine speed

ENGINE SPEED [rpm]

P/N position switch

R position switch

D position switch

Sport mode switch

L position switch

Closed throttle position switch

N POSITION SW [ON/OFF] R POSITION SW [ON/OFF] D POSITION SW [ON/OFF] S POSITION SW [ON/OFF] L POSITION SW [ON/OFF] CLOSED THL/SW [ON/OFF]

Wide open throttle position W/O THRL/ switch P-SW [ON/OFF]

TCM input signals

Main signals

Description

Remarks

I Vehicle speed computed from signal of revolution sensor is displayed.

When racing engine in “N” or “P” position with vehicle stationary, CONSULT-II data may not indicate 0 km/h (0 mph).

X

—

X

—

I Throttle position sensor signal voltage is displayed.

—

X

—

I CVT fluid temperature sensor signal voltage is displayed. I Signal voltage lowers as fluid temperature rises.

—

X

—

I Source voltage of TCM is displayed.

—

X

X

I Engine speed, computed from engine speed signal, is displayed.

Engine speed display may not be accurate under approx. 800 rpm. It may not indicate 0 rpm even when engine is not running.

—

I ON/OFF state computed from signal of P/N position SW is displayed.

—

—

I ON/OFF state computed from signal of R position SW is displayed.

—

—

I ON/OFF state computed from signal of D position SW is displayed.

—

X

—

I ON/OFF status, computed from signal of Sport mode SW, is displayed.

—

X

—

I ON/OFF status, computed from signal of L position SW, is displayed.

—

—

I ON/OFF status, computed from signal of closed throttle position SW, is displayed.

—

—

I ON/OFF status, computed from signal of wide open throttle position SW, is displayed.

—

X

X

X

X

X

AT-21

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item

Gear position

Display

Description

Remarks

X

I Gear position (when use manual mode) data used for computation by TCM, is displayed.

—

—

X

I Selector lever position I A specific value used for data, used for computacontrol is displayed if failtion by TCM, is dissafe is activated due to played. error.

—

X

I Vehicle speed data, used for computation by TCM, is displayed.

X

I A specific value used for I Throttle position data, used for computation by control is displayed if failsafe is activated due to TCM, is displayed. error.

X

I Control value of line pressure solenoid valve, computed by TCM from each input signal, is displayed.

—

X

I Control value of torque converter clutch solenoid valve, computed by TCM from each input signal, is displayed.

—

TCM input signals

GEAR —

Selector lever position

Vehicle speed

Throttle position

Line pressure duty

Torque converter clutch solenoid valve duty

Main signals

SLCT LVR POSI

VEHICLE SPEED [km/h] or [mph] THROTTLE POSI [/8] LINE PRES DTY [%]

—

—

TCC S/V DUTY [%] —

Self-diagnosis display lamp (SPORT or CVT indicator lamp)

PAT MONI LAMP [ON/OFF]

CVT fluid pressure sensor

LINE PRESSURE [V]

I Control status of SPORT or CVT indicator lamp is displayed.

—

—

X

X

—

I CVT fluid pressure sensor signal voltage is displayed.

—

X

I Primary pulley speed computed from signal of primary pulley speed sensor is displayed.

—

—

—

I Secondary pulley speed computed from signal of secondary speed sensor is displayed.

—

—

Primary pulley speed sensor

I/P PULLY SPD [rpm]

Secondary pulley speed sensor

O/P PULLY SPD [rpm]

Stop lamp switch

BRAKE SW [ON/OFF]

X

—

I ON/OFF position signal of stop lamp switch is displayed.

—

CLSD THL POSI [ON/OFF]

—

—

I Idle status judged from throttle position sensor signal is displayed.

—

ABS SIGNAL [ON/OFF]

X

—

I ABS operation signal (ON/OFF) from ABS control unit is displayed.

—

MANU MODE SW [ON/OFF]

X

—

I ON/OFF position signal of manual mode switch is displayed.

—

Idle judgement

ABS signal

Manual mode switch

X

AT-22

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitor item Item

Non-manual mode switch

Up switch

Down switch

Step motor coil A

Step motor coil B

Step motor coil C

Step motor coil D

Display

I ON/OFF position signal of non-manual mode switch is displayed.

—

X

—

I ON/OFF position signal of up switch is displayed.

—

X

—

I ON/OFF position signal of down switch is displayed.

—

—

I Control valve of step motor coil A, computed by TCM from each input signal is displayed.

—

—

I Control valve of step motor coil B, computed by TCM from each input signal is displayed.

—

—

I Control valve of step motor coil C, computed by TCM from each input signal is displayed.

—

—

—

I Control valve of step motor coil D, computed by TCM from each input signal is displayed.

—

—

X

I Real CVT ratio operated TCM is displayed.

—

—

X

I Step motor position is displayed.

—

—

X

I Real line pressure calculated from line pressure sensor voltage with TCM is displayed.

—

—

—

I Target primary pulley speed operated with TCM is displayed.

—

—

—

I Target changing the speed ratio operated with TCM is displayed.

—

—

—

I Target step motor position operated with TCM is displayed.

—

X

UP SW [ON/OFF] DOWN SW [ON/OFF] S/M COIL [A] [ON/OFF]

S/M COIL [B] [ON/OFF]

S/M COIL [C] [ON/OFF]

S/M COIL [D] [ON/OFF]

Step

PLY CONT STEP [step]

Line pressure

LINE PRESSURE [MPa]

Step 2

—

NON M MODE SW [ON/OFF]

CVT RATIO [—]

CVT ratio 2

Remarks

Main signals

CVT ratio

Pulley rpm⋅in 2

Description

TCM input signals

—

—

—

T RPM [rpm]

T RATIO [—]

T STEP [step]

X: Applicable —: Not applicable

AT-23

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

WORK SUPPORT MODE WITH CONSULT-II

Data link connector

1. 2. 3.

Turn ignition switch “OFF”. Connect CONSULT-II to Data link connector. Data link connector is located in left side dash panel. Turn ignition switch “ON”.

4.

Touch “START”.

5.

Touch “CVT”.

6.

Touch “WORK SUPPORT”.

7. 8.

Touch “ENGINE BRAKE ADJUSTMENT”. Touch “START”.

NRS071

SAT586J

SAT651J

SAT732J

SAT933J

AT-24

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

9.

SAT934J

Set “ENGINE BRAKE LEVEL” by touching “UP” or “DOWN”. ENGINE BRAKE LEVEL 0: Initial set value (Engine brake level control is activated) OFF: Engine brake level control is disactivated. 10. Turn ignition switch “OFF”, wait at least 5 seconds and then turn ignition switch “ON”. 11. Engine brake level set is completed. CAUTION: Mode of “+1” “0” “-1” “-2” “OFF” can be selected by pressing the “UP” “DOWN” on CONSULT screen. However, do not select mode other than “0” and “OFF”. If the “+1” or “-1” or “-2” is selected, that might cause the abnormality of drivability.

DIAGNOSTIC PROCEDURE WITHOUT CONSULT-II NCAT0022S07 OBD Self-diagnostic Procedure (With GST) NCAT0022S0701 Refer to EC section [“Generic Scan Tool (GST)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].

OBD Self-diagnostic Procedure (No Tools)

NCAT0022S0702

Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”].

TCM Self-diagnostic Procedure (No Tools)

=NCAT0022S0703

Preparation 1. Turn ignition switch to “OFF” position. 2. Disconnect the throttle position switch harness connector. 3. Turn ignition switch to “ON” position. 4. Check continuity of the closed throttle position switch. Continuity should exist. (If continuity does not exist, check throttle opener and closed throttle position switch. Then increase vacuum until closed throttle position switch shows continuity.) 5. Connect the throttle position switch harness connector. 6. Warm up the engine. 7. Turn the ignition switch from ON to OFF two more times, and then turn to OFF. 8. In the “P” position of the selector lever, turn the ignition switch ON, and verify that the CVT warning lamp turns on for about 2 seconds. 9. Turn the ignition switch OFF. 10. Press the brake pedal, and shift the selector lever to the “D” position. 11. Turn the ignition switch ON. 12. Release the brake, and shift the selector lever to the “L” position. 13. Fully depress both brake and accelerator pedals all the way to the floor. Without releasing the brake and accelerator pedals, shift the selector lever to the “D” position. 14. Read the display from the CVT warning lamp to complete the diagnosis.

AT-25

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d)

Judgement of Self-diagnosis Code

NCAT0022S0704

CVT or SPORT indicator lamp* All judgement flickers are the same.

1st judgement flicker is longer than others.

Self diagnosis start Start signal 10 judgement flickers

Light

Light

Shade

Shade

SAT436FA

SAT437FA

All circuits that can be confirmed by self-diagnosis are OK.

Secondary speed sensor (VEHICLE SPEED SENSOR CVT) circuit is short-circuited or disconnected. ⇒ Go to VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) (DTC: 0720), AT-62.

2nd judgement flicker is longer than others.

3rd judgement flicker is longer than others.

Light Light Shade Shade

SAT439FA

SAT441FA

Primary speed sensor circuit is short-circuited or disconnected. ⇒ Go to PRIMARY SPEED SENSOR (DTC: 0715), AT-59.

Throttle position sensor circuit is short-circuited or disconnected. ⇒ Go to THROTTLE POSITION SENSOR (DTC: 1705), AT-79.

4th judgement flicker is longer than others.

5th judgement flicker is longer than others.

Self diagnosis start Light

Light Shade

Shade

SAT443FA

Step motor circuit is short-circuited or disconnected. ⇒ Go to STEP MOTOR (DTC: 1777), AT-86.

SAT445FA

CVT fluid pressure sensor circuit is short-circuited or disconnected. ⇒ Go to CVT FLUID PRESSURE SENSOR (DTC: 1791), AT-94.

AT-26

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) CVT or SPORT indicator lamp* 7th judgement flicker is longer than others.

6th judgement flicker is longer than others.

Light

Light

Shade

Shade SAT447FA

SAT449FA

Line pressure solenoid valve circuit is short-circuited or disconnected. ⇒ Go to LINE PRESSURE SOLENOID VALVE (DTC: 0745), AT-74.

Lock up solenoid valve circuit is short-circuited or disconnected. ⇒ Go to TORQUE CONVERTER CLUTCH SOLENOID VALVE (DTC: 0740), AT-69.

8th judgement flicker is longer than others.

9th judgement flicker is longer than others.

Self diagnosis start Light

Light

Shade

Shade

SAT451FA

SAT453FA

CVT fluid temperature sensor is disconnected or TCM power source circuit is damaged. ⇒ Go to CVT FLUID TEMPERATURE SENSOR (DTC: 0710) AND TCM POWER SOURCE, AT-54.

Engine speed signal circuit is short-circuited or disconnected. ⇒ Go to ENGINE SPEED SIGNAL (DTC: 0725), AT-66.

10th judgement flicker is longer than others.

Flickers as shown below.

Light Light Shade

Shade

SAT455FA

I When “4th judgement flicker” and/or “6th judgement flicker” is displayed, inspect “STEP MOTOR (DTC: 1777)” and/or “LINE PRESSURE SOLENOID VALVE (DTC: 0745)”. I When neither “4th judgement flicker” nor “6th judgement flicker” are displayed, replace TCM. ⇒ Go to CVT SAFE FUNCTION, AT-99.

SAT457FA

Battery voltage is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting TCM connectors — This is not a problem)

AT-27

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) CVT or SPORT indicator lamp* Lamp does not come on.

Self diagnosis start Light

Shade SAT653J

PNP switch, stop lamp switch or throttle position switch circuit is disconnected or TCM is damaged. ⇒ Go to TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS, AT-105. t1 = 2.5 seconds t2 = 2.0 seconds t3 = 1.0 second *CVT indicator lamp: Hyper CVT M6 SPORT indicator lamp: Hyper CVT

t4 = 1.0 second

AT-28

TROUBLE DIAGNOSIS — INTRODUCTION Introduction

Introduction Sensors

TCM

Solenoid valves

ECM

SAT631IA

CAUSE INFO.

SAT632I

NCAT0023

The TCM receives a signal from the vehicle speed sensor, throttle position sensor or PNP switch and provides shift control or lock-up control via step motor and CVT solenoid valves. The TCM also communicates with the ECM by means of a signal sent from sensing elements used with the OBD-related parts of the CVT system for malfunction-diagnostic purposes. The TCM is capable of diagnosing malfunctioning parts while the ECM can store malfunctions in its memory. Input and output signals must always be correct and stable in the operation of the CVT system. The CVT system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow”. Refer to AT-32. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example (AT-31) should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle. Also check related Service bulletins for information.

SEF234G

AT-29

TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)

DIAGNOSTIC WORKSHEET Information from Customer KEY POINTS WHAT ..... Vehicle & CVT model WHEN..... Date, Frequencies WHERE..... Road conditions HOW..... Operating conditions, Symptoms Customer name

MR/MS

Model & Year

VIN

Trans. model

Engine

Mileage

Incident Date

Manuf. Date

In Service Date

Frequency

l Continuous

l Intermittent

l Vehicle does not move. Symptoms

(

times a day)

( l Any position l Particular position)

l Lockup malfunction l Shift point too high or too low. l Shift shock or slip

(lN,D

l Lockup

l Noise or vibration l No pattern select l Others (

)

SPORT indicator lamp or CVT indicator (warning) lamp

Blinks for about 8 seconds. l Continuously lit

l Not lit

Malfunction indicator (MI)

l Continuously lit

l Not lit

AT-30

l Any drive position)

=NCAT0023S01 NCAT0023S0101

TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d)

Diagnostic Worksheet

=NCAT0023S0102

1.

l Read the Fail-safe and listen to customer complaints.

AT-6

2.

l CHECK CVT FLUID

AT-34

l Leakage (Follow specified procedure) l Fluid condition l Fluid level 3.

l Perform STALL TEST and LINE PRESSURE TEST.

AT-34, 35

l Stall test — Mark possible damaged components/others. l Forward clutch

l Reverse brake l Engine l Line pressure is low

l Line Pressure test — Suspected parts: 4.

l Perform all ROAD TEST and mark required procedures.

AT-36

4-1. Check before engine is started.

AT-37

l SELF-DIAGNOSTIC PROCEDURE — Mark detected items. l l l l l l l l l l l l l l l

PNP switch, AT-48. CVT fluid temperature sensor, AT-54. Vehicle speed sensor (Secondary speed sensor), AT-62. Engine speed signal, AT-66. Torque converter clutch solenoid valve, AT-69. Line pressure solenoid valve, AT-74. Step motor, AT-86, 91. CVT fluid pressure sensor, AT-94. Throttle position sensor, AT-79. Stop lamp and throttle position switches. CVT fluid temperature sensor and TCM power source, AT-54. Primary speed sensor, AT-59. PNP switch, stop lamp switch, throttle position switch AT-105. Battery Others

5.

l For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts.

AT-19

6.

l Perform all ROAD TEST and re-mark required procedures.

AT-36

7.

l Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts. Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible symptoms and the component inspection orders.)

AT-41 AT-54

8.

l Erase DTC from TCM and ECM memories.

AT-16

AT-31

TROUBLE DIAGNOSIS — INTRODUCTION Work Flow

Work Flow HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR

=NCAT0024 NCAT0024S01

A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Make good use of the two sheets provided, “INFORMATION FROM CUSTOMER” (AT-30) and “DIAGNOSTIC WORKSHEET” (AT-31), to perform the best troubleshooting possible.

AT-32

TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d)

WORK FLOW CHART

=NCAT0024S02

CHECK IN H

LISTEN TO CUSTOMER COMPLAINTS AND FILL OUT “INFORMATION FROM CUSTOMER”, *1

F

Refer to FAIL-SAFE Service Notice or Precautions, *3.

F

Refer to CVT Fluid Check, *4.

F

Refer to Stall Test and Line Pressure Test, *5.

F

Follow ROAD TEST procedure, *6.

H

CHECK, PRINT OUT OR WRITE DOWN (1ST TRIP) DTC AND FREEZE FRAME DATA. (PRE-CHECK) THEN ERASE. PASTE IT IN REPAIR ORDER SHEET. ALSO CHECK RELATED SERVICE BULLETINS. H

CHECK A/T FLUID LEVEL AND CONDITION. IF NG, PLACE CHECK ON THE DIAGNOSTIC WORKSHEET, *2. H

PERFORM STALL TEST AND LINE PRESSURE TEST. H

PERFORM “DTC CONFIRMATION PROCEDURE” IF THE (1ST TRIP) DTC IS AVAILABLE. PERFORM ROAD TEST AND PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC WORKSHEET.

NG items including OBD No NG item or NG items (1st trip) DTC or TCM selfnot including any OBD diagnostic item DTC or TCM self-diagnostic H items ● FOR OBD or TCM SELF-DIAGNOSIS NG ITEMS: F -INSPECT EACH COMPONENT. -REPAIR/REPLACE. ● PERFORM DTC CONFIRMATION PROCEDURE OR ROAD TEST AND PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC WORKSHEET AGAIN.

E

●

●

Refer to CONSULT-II, *7. Perform ROAD TEST for all items. Proceed if self-diagnosis detects no malfunction. (Non-self-diagnostic items, especially those that require CVT removal, should be repaired in the following steps.)

H

H ●

● ●

FOR ALL REMAINING MALFUNCTIONS: F -INSPECT EACH COMPONENT. -REPAIR/REPLACE. PERFORM ROAD TEST AND CONFIRM ALL MALFUNCTIONS ARE ELIMINATED.

Refer to ● ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION, *8 - *9. ● TROUBLE DIAGNOSIS FOR DTC, *10 - *11. ● TROUBLE DIAGNOSES FOR SYMPTOMS, *12.

H

ERASE DTC FROM TCM AND ECM MEMORIES.

F

Refer to HOW TO ERASE DTC, *13.

F

Refer to DTC CONFIRMATION PROCEDURE. *14 - *15.

H

NG

FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and DTC CONFIRMATION PROCEDURE. Then, erase the unnecessary (already fixed) 1st trip DTCs in ECM and TCM.

OK E

CHECK OUT SAT086JC

*1: *2: *3: *4: *5:

AT-30 AT-31 AT-6 AT-34 AT-34, 35

*6: *7: *8: *9: *10:

*11: *12: *13: *14: *15:

AT-36 AT-18 AT-15 AT-26 AT-48

AT-33

AT-94 AT-110 AT-16 AT-49 AT-95

TROUBLE DIAGNOSIS — BASIC INSPECTION CVT Fluid Check

CVT Fluid Check

NCAT0025

FLUID LEAKAGE CHECK 1.

NCAT0025S01

3.

Clean area suspected of leaking. — for example, mating surface of converter housing and transmission case. Start engine, apply foot brake, place selector lever in “D” position and wait a few minutes. Stop engine.

4.

Check for fluid leakage.

2.

SAT767B

Fluid leakage

SAT288G

FLUID CONDITION CHECK Fluid color

NCAT0025S02

Suspected problem

Dark or black with burned odor

Wear of frictional material

Milky pink

Water contamination — Road water entering through filler tube or breather

Varnished fluid, light to dark brown and Oxidation — Over or under filling, — tacky Overheating SAT638A

FLUID LEVEL CHECK

NCAT0025S03

Refer to MA section (“Checking CVT Fluid”, “CHASSIS AND BODY MAINTENANCE”).

Stall Test STALL TEST PROCEDURE 1. 2.

NCAT0026 NCAT0026S01

Check CVT fluid and engine oil levels. If necessary, add. Drive vehicle for approx. 10 minutes or until engine oil and CVT fluid reach operating temperature. CVT fluid operating temperature: 50 - 80°C (122 - 176°F)

SAT647B

AT-34

TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d)

3. 4. I

Set parking brake and block wheels. Install a tachometer where it can be seen by driver during test. It is good practice to mark the point of specified engine rpm on indicator.

5.

Start engine, apply foot brake, and place selector lever in D position. Accelerate to wide open throttle gradually while applying foot brake. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide open for more than 5 seconds. Stall revolution: 2,350 - 2,850 rpm

SAT513G

6. 7.

Less than 5 sec.

I

SAT514G

8. 9. I

Move selector lever to “N” position. Cool off CVT fluid. Run engine at idle for at least one minute.

SAT771B

Line Pressure Test LINE PRESSURE TEST PORTS

NCAT0027 NCAT0027S01

Location of line pressure test ports are shown in the illustration. I Always replace pressure plugs as they are self-sealing bolts.

Line pressure test port

SAT670J

LINE PRESSURE TEST PROCEDURE 1. 2.

NCAT0027S02

Check CVT fluid and engine oil levels. If necessary, add fluid or oil. Drive vehicle for approx. 10 minutes or until engine oil and CVT fluid reach operating temperature. CVT fluid operating temperature: 50 - 80°C (122 - 176°F)

SAT647B

AT-35

TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test (Cont’d)

3.

Install pressure gauge to corresponding line pressure port.

4. I

Set parking brake and block wheels. Continue to depress brake pedal fully while line pressure test is being performed at stall speed.

SAT513G

5. I

Start engine and measure line pressure at idle and stall speed. When measuring line pressure at stall speed, follow the stall test procedure. Line pressure: Refer to SDS, AT-120.

SAT493G

Road Test

ROAD TEST PROCEDURE

DESCRIPTION I

1. Check before engine is started.

I 1. 2.

NCAT0028 NCAT0028S01

The purpose of the test is to determine overall performance of CVT and analyze causes of problems. The road test consists of the following three parts: Check before engine is started Cruise test

2. Cruise test. SAT692J

I I

Before road test, familiarize yourself with all test procedures and items to check. Conduct tests on all items until specified symptom is found. Troubleshoot items which check out No Good after road test. Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION” and “TROUBLE DIAGNOSIS FOR SYMPTOMS”, AT-15, AT-26 and AT-110.

SAT496G

AT-36

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

1. CHECK BEFORE ENGINE IS STARTED 1

=NCAT0028S02

CHECK SPORT OR CVT INDICATOR LAMP

1. Park vehicle on flat surface. 2. Move selector lever to “P” position.

SPORT or CVT

SAT967IA

3. Turn ignition switch to “OFF” position. Wait at least 5 seconds. 4. Turn ignition switch to “ON” position. (Do not start engine.) 5. Does CVT or SPORT indicator lamp come on for about 2 seconds? Yes or No Yes

©

GO TO 2.

No

©

Stop ROAD TEST.

2

CHECK CVT OR SPORT INDICATOR LAMP

Does CVT or SPORT indicator lamp flicker for about 8 seconds? Yes or No Yes

©

Perform self-diagnosis and check NG items on the DIAGNOSTIC WORKSHEET, AT-31. Refer to TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS), AT-25.

No

©

1. Turn ignition switch to “OFF” position. 2. Perform self-diagnosis and note NG items. Refer to TCM SELF-DIAGNOSIS PROCEDURE (NO TOOLS), AT-25.

3

TEST DRIVE

Drive the vehicle and verify that there are no abnormalities.

©

TEST END

2. CRUISE TEST I

With CONSULT-II I I

NCAT0028S04

Check all items listed in Parts 1 through 3. NCAT0028S0401

Using CONSULT-II, conduct a cruise test and record the result. Print the result and ensure that shifts and lock-ups take place as per Shift Schedule.

SAT601J

AT-37

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

CONSULT-II Setting Procedure

Data link connector

NCAT0028S0402

1. 2.

Turn ignition switch “OFF”. Connect CONSULT-II to Data link connector. Data link connector is located in left side dash panel.

3. 4.

Turn ignition switch “ON”. Touch “START”.

5.

Touch “CVT”.

6.

Touch “DATA MONITOR”.

7. 8.

Touch “MAIN SIGNALS” to set recording condition. See “Numerical Display”, “Barchart Display” or “Line Graph Display”. Touch “START”.

NRS071

SAT586J

SAT651J

SAT732J

9.

PAT902H

AT-38

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

10. When performing cruise test, touch “Store Data”.

PAT071H

11. After finishing cruise test part 1, touch “STOP”.

PAT072H

12. Touch “STORE”.

PAT301C

13. Touch “DISPLAY”.

SAT608J

SAT609J

AT-39

TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d)

14. Touch “PRINT”. 15. Check the monitor data printed out. 16. Continue cruise test part 2 and 3.

SAT610J

Without CONSULT-II I

NCAT0028S0403

Throttle position sensor can be checked by voltage across terminals 41 and 42 of TCM. Refer to “Road Test”, AT-36.

SAT417J

AT-40

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value

TCM Terminals and Reference Value

NCAT0030

PREPARATION I

NCAT0030S01

Measure voltage between each terminal and terminal 25 or 48 by following “TCM INSPECTION TABLE”.

Terminal 25 or p 48 p SAT216J

TCM HARNESS CONNECTOR TERMINAL LAYOUTNCAT0030S02

SAT403J

TCM INSPECTION TABLE

NCAT0030S03

(Data are reference values.) Terminal No.

1

2

3

Wire color

OR/L

P/B

GY/R

Item

Judgement standard

Condition When releasing accelerator pedal after warming up engine.

Line pressure solenoid valve

Approx. 2.8V

When depressing accelerator pedal Approx. 1.4V fully after warming up engine. When releasing accelerator pedal after warming up engine.

Line pressure solenoid valve (with dropping resistor)

Approx. 11.0V

When depressing accelerator pedal Approx. 4.0V fully after warming up engine.

Torque converter clutch solenoid valve

When CVT performs lock-up.

Approx. 12.0V

When CVT does not perform lockup.

Approx. 0V

5 *1

W/L

DT1

—

—

6 *1

W/PU

DT2

—

—

7 *1

R/W

DT3

—

—

8 *1

L/R

DT5

—

—

9 *1

LG/B

DT4

—

—

10

G/W

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

Approx. 0V

Power source

AT-41

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

Wire color

11

PU

12

L/W

13

15 *1

16

17

OR/B

Item Step motor A Step motor B

Y

LG

Approx. 0V

ABS control unit

When driving slowly.

Change 0 Battery voltage

Same as No. 10

L/Y

Step motor C

21

P/L

Step motor D

27

L/OR

—

When releasing accelerator pedal after warming up engine.

20

B

—

When depressing accelerator pedal more than half-way after warming Battery voltage up engine.

Power source

25

Battery voltage

Wide open throttle position switch (in throttle position switch)

G/W

BR/Y

When CVT or SPORT indicator lamp does not illuminate

When releasing accelerator pedal after warming up engine.

19

23

Approx. 0V

Closed throttle position switch (in throttle position switch)

SB

GY

When CVT or SPORT indicator lamp illuminates

—

18

22

Within 2 seconds after key switch “ON”, the time measurement by 30.0 msec using the pulse width measurement function (Hi level) of CONSULT-II. I CONSULT-II cable connected to data link connector. 10.0 msec I This inspection cannot be measured by circuit tester.

CVT or SPORT indicator lamp

PU/Y

Judgement standard

Condition

Battery voltage

When depressing accelerator pedal Approx. 0V after warming up engine.

Within 2 seconds after key switch “ON”, the time measurement by 30.0 msec using the pulse width measurement function (Hi level) of CONSULT-II. I CONSULT-II cable connected to data link connector. 10.0 msec. I This inspection cannot be measured by circuit tester. When SPORT mode switch in “ON” Approx. 0V position.

Sport mode switch

When SPORT mode switch in “OFF” position.

Approx. 10V

When ABS operates.

Approx. 0V

When ABS does not operate.

5.6 - 10.0V

ABS control unit

Ground

— When setting selector lever to “L” position.

PNP switch “L” position

— Battery voltage

When setting selector lever to other Approx. 0V positions.

AT-42

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

28

Wire color

W/L

Item

Power source (Memory backup)

Judgement standard

Condition When turning ignition switch to “OFF”.

Battery voltage

When turning ignition switch to “ON”.

Battery voltage

or

When driving (D position, 20 km/h), the pulse measurement by Secondary speed using the pulse measurement function of CONSULT-II. sensor I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.

29

G/R

30 *2

G/B

—

—

—

31 *2

GY/L

—

—

—

32

33

34

35

36

37

G

Throttle position sensor (Power source)

PU/W

Indicator control unit

LG

PNP switch “D” position

G/W

G/R

W/G

Approx. 600 Hz

When turning ignition switch to “ON”

4.5 - 5.5V

When turning ignition switch to “OFF”

Approx. 0V

When setting selector lever to any position.

1.5 - 2.0V

When setting selector lever to “D” position.

Battery voltage

When setting selector lever to other Approx. 0V positions. When setting selector lever to “R” position.

PNP switch “R” position

Battery voltage

When setting selector lever to other Approx. 0V positions. When setting selector lever to “N” or “P” position.

PNP switch “N” or “P” position

Battery voltage

When setting selector lever to other Approx. 0V positions. When engine runs at idle speed.

Approx. 1.0V

When engine runs at stall speed.

Approx. 4.0V

CVT fluid pressure sensor

38

G/Y

Primary speed sensor

39

L/OR

Engine speed signal

When driving (L position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II. I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.

When engine runs at idle speed.

AT-43

Approx. 900 Hz

0.5 - 1.5V

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No.

Wire color

Item

41

GY

Throttle position sensor

42

B/W

Throttle position sensor (Ground)

45

R/G

Stop lamp switch

46

47

48

P/L

Y/PU

B

Judgement standard

Condition

Fully-closed throttle: When depressing accelerator pedal Approximately slowly after warming up engine. 0.3V (Voltage rises gradually in response Fully-open to throttle position.) throttle: Approximately 3V — When depressing brake pedal

Battery voltage

When releasing brake pedal

Approx. 0V

CVT fluid pressure sensor (Power source)

—

CVT fluid temperature sensor

4.5 - 5.5V

When CVT fluid temperature is 20°C (68°F).

Approximately 1.5V

When CVT fluid temperature is 80°C (176°F).

Approximately 0.5V

Ground

—

*1: This terminal is connected to the ECM. *2: These terminals are connected to the Data link connector for CONSULT-II.

AT-44

—

—

TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN

Wiring Diagram — CVT — MAIN

NCAT0031

BATTERY

FUSE BLOCK (J/B)

Refer to EL-POWER.

: Detectable line for DTC : Non-detectable line for DTC : LHD models ENGINE CONTROL MODULE RELAY

: RHD models

OFF

ON

STOP LAMP SWITCH

STOP LAMP SWITCH OFF

ON

FUSE BLOCK (J/B)

TCM (TRANSMISSION CONTROL MODULE)

ECM

Refer to last page (foldout page).

YAT201

AT-45

TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN (Cont’d)

TCM TERMINALS AND REFERENCE VALUE

NCAT0031S01

Remarks: Specification data are reference values. Terminal No.

10

Wire color

G/W

19

G/W

25

B

28

48

W/L

B

Item

When turning ignition switch to “ON”.

Battery voltage

When turning ignition switch to “OFF”.

Approx. 0V

Power source

Power source

Same as No. 10

Ground

—

Power source (Memory backup)

—

When turning ignition switch to “OFF”.

Battery voltage

When turning ignition switch to “ON”.

Battery voltage

or

Ground

—

DIAGNOSTIC PROCEDURE 1

Judgement standard

Condition

—

NCAT0031S03

CHECK TCM POWER SOURCE

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 10, 19, 28 and ground. Voltage: Battery voltage 3. Turn ignition switch to “OFF” position. 4. Check voltage between TCM terminal 28 and ground. Voltage: Battery voltage

SAT332J

OK or NG OK

©

GO TO 2.

NG

©

Check the following items: I Harness for short or open between ignition switch and TCM terminals 10, 19 and 25 (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”).

AT-46

TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — CVT — MAIN (Cont’d)

2

CHECK TCM GROUND CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check continuity between terminals 25, 48 and ground. Continuity should exist.

SAT333J

If OK, check harness for short to ground and short to power. OK or NG OK

©

INSPECTION END

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

AT-47

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description

Description I I

NCAT0032

The PNP switch assembly includes a transmission range switch. The transmission range switch detects the selector lever position and sends a signal to the TCM.

TCM TERMINALS AND REFERENCE VALUE

NCAT0032S01

Remarks: Specification data are reference values. Terminal No.

27

Wire color

L/OR

34

LG

35

G/W

36

G/R

Item

Judgement standard

Condition

PNP switch “L” position

PNP switch “D” position

PNP switch “R” position

PNP switch “N” or “P” position

When setting selector lever to “L” position.

Battery voltage

When setting selector lever to other positions.

Approx. 0V

When setting selector lever to “D” position.

Battery voltage

When setting selector lever to other positions.

Approx. 0V

When setting selector lever to “R” position.

Battery voltage

When setting selector lever to other positions.

Approx. 0V

When setting selector lever to “N” or “P” position.

Battery voltage

When setting selector lever to other positions.

Approx. 0V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

Check items (Possible cause)

: PNP SW/CIRC : P0705

TCM does not receive the correct voltage signal from the switch based on the gear position.

: MI Code No. 0705

AT-48

I Harness or connectors (The PNP switch circuit is open or shorted.) I PNP switch

NCAT0032S02

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0032S03

SAT651J

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

SAT654J

3) 4)

Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. Start engine and maintain the following conditions for at least 15 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is “NG”, go to “Diagnostic Procedure”, AT-51. With GST

Follow the procedure “With CONSULT-II”.

AT-49

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Wiring Diagram — AT — PNP/SW

Wiring Diagram — AT — PNP/SW

NCAT0199

YAT251

AT-50

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure

Diagnostic Procedure 1

NCAT0033

CHECK PNP SWITCH CIRCUIT (With CONSULT-II) With CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.

SAT651J

3. Read out “P/N”, “R”, “D” and “L” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. OK or NG OK

©

GO TO 3.

NG

©

Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)

2

CHECK PNP SWITCH CIRCUIT (Without CONSULT-II) Without CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 27, 34, 35, 36 and ground while moving selector lever through each position. Voltage: B: Battery voltage 0: 0V Terminal No. Lever position

MTBL0312 OK or NG

OK

©

GO TO 3.

NG

©

Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)

AT-51

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Diagnostic Procedure (Cont’d)

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-49. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-52

DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Component Inspection

Component Inspection

=NCAT0034

PARK/NEUTRAL POSITION SWITCH 1.

Check continuity between terminals 1 and 2 and between terminals 3 and 5, 6, 7, 8, 9 while moving manual shaft through each position. Lever position

2. 3. 4. 5. 6.

NCAT0034S01

Terminal No.

P

3—7

R

3—8

N

3—9

D

3—6

L

3—5

1—2

1—2

If NG, check again with control cable disconnected from manual shaft of CVT assembly. Refer to step 1. If OK on step 2, adjust control cable. Refer to AT-114. If NG on step 2, remove PNP switch from CVT and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-114. If NG on step 4, replace PNP switch.

AT-53

DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Description 2.5

Description

2.0

The CVT fluid temperature sensor detects the CVT fluid temperature and sends a signal to the TCM.

NCAT0035

1.5 1.0 0.5 °C (°F)

0

(-40) (-4) (32) (68) (104) (140) (176) (212) (248) (284) (320)

SAT021J

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0035S01 Remarks: Specification data are reference values. Monitor item CVT fluid temperature sensor

Condition

Specification

Cold [20°C (68°F)] " Hot [80°C (176°F)]

Approximately 1.5V " Approximately 0.5V

TCM TERMINALS AND REFERENCE VALUE

NCAT0035S02

Remarks: Specification data are reference values. Terminal No.

Wire color

42

B

47

Y/PU

Item

Judgement standard

Condition

Throttle position sensor (Ground)

—

CVT fluid temperature sensor

—

When CVT fluid temperature is 20°C (68°F).

Approximately 1.5V

When CVT fluid temperature is 80°C (176°F).

Approximately 0.5V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0035S03

Check items (Possible cause)

: ATF TEMP SEN/CIRC : P0710

TCM receives an excessively low or high voltage from the sensor.

: MI Code No. 0710

AT-54

I Harness or connectors (The sensor circuit is open or shorted.) I CVT fluid temperature sensor

DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0035S04

SAT651J

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1)

SAT654J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine and maintain the following conditions for at least 10 minutes (Total). (It is not necessary to maintain continuously.) ENG SPEED: 450 rpm or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3 V Selector lever: D position If the check result is NG, go to “Diagnostic Procedure”, AT-57. With GST Follow the procedure “With CONSULT-II”.

AT-55

DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Wiring Diagram — AT — FTS

Wiring Diagram — AT — FTS

NCAT0200

CONTROL VALVE (CVT FLUID TEMPERATURE SENSOR)

: Detectable line for DTC : Non-detectable line for DTC

TCM (TRANSMISSION CONTROL MODULE)

ECM

YAT203

AT-56

DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure

Diagnostic Procedure 1

NCAT0036

CHECK CVT FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY

1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminals 6 and 7 when CVT is cold. Resistance: Cold [20°C (68°F)] Approximately 2.5 kΩ

SAT419JA

4. Reinstall any part removed. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Replace CVT assembly

2

CHECK INPUT SIGNAL OF CVT FLUID TEMPERATURE SENSOR (With CONSULT-II) With CONSULT-II

1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V OK or NG OK

©

GO TO 4.

NG

©

Check the following item: I Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

AT-57

DTC P0710 CVT FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure (Cont’d)

3

CHECK INPUT SIGNAL OF CVT FLUID TEMPERATURE SENSOR (Without CONSULT-II) Without CONSULT-II

1. Start engine. 2. Check voltage between TCM terminal 47 and ground while warming up CVT. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V

SAT420JA

3. Turn ignition switch to “OFF” position. 4. Disconnect TCM harness connector. 5. Check continuity between terminal 42 and ground. Continuity should exist.

SAT421J

If OK, check harness for short to ground and short to power. OK or NG OK

©

GO TO 4.

NG

©

Check the following item: I Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-55. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-58

DTC P0715 PRIMARY SPEED SENSOR Description

Description

NCAT0220

The primary speed sensor detects the primary pulley revolution speed and sends a signal to the ECM.

TCM TERMINALS AND REFERENCE VALUE

NCAT0220S01

Remarks: Specification data are reference values. Terminal No.

Wire color

38

G/Y

Item

Judgement standard

Condition

Primary speed sensor

When driving (L position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II.

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Approx. 900 Hz

NCAT0220S02

Malfunction is detected when ...

Check items (Possible cause)

TCM does not receive the proper voltage signal from the sensor.

I Harness or connectors (The sensor circuit is open or shorted.) I Primary speed sensor

: PRI SPEED SIG/CIRC : P0715 : MI Code No. 0715

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0220S03

SAT651J

CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

SAT971J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to “Diagnostic Procedure”, AT-61. With GST

Follow the procedure “With CONSULT-II”.

SAT654J

AT-59

DTC P0715 PRIMARY SPEED SENSOR Wiring Diagram — AT — VSSA/T

Wiring Diagram — AT — VSSA/T PRIMARY SPEED SENSOR

NCAT0221

: Detectable line for DTC : Non-detectable line for DTC

TCM (TRANSMISSION CONTROL MODULE)

ECM

YAT204

AT-60

DTC P0715 PRIMARY SPEED SENSOR Diagnostic Procedure

Diagnostic Procedure 1

NCAT0222

CHECK PRIMARY SPEED SENSOR

Refer to “Component Inspection” AT-65. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Repair or replace primary speed sensor.

2

CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II

1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “I/P PULLY SPD” while driving. Check the value changes according to driving speed. (Almost same value as engine speed) OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM, ECM and primary speed sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-62. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

Component Inspection REVOLUTION SENSOR 1. 2.

NCAT0223 NCAT0223S01

Jacking up the vehicle. Check pulse by using the pulse measurement function of CONSULT-II when front wheel rotating. I CONSULT-II cable connected to data link connector. At front wheel rotating (L position, 20 km/h): Approx. 900 Hz

CONSULT-II

To data link connector

DDL

PULSE

NAT314

AT-61

DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Description

Description

NCAT0038

The vehicle speed sensor CVT secondary speed sensor detects the revolution of the idler gear parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed.

TCM TERMINALS AND REFERENCE VALUE

NCAT0038S01

Remarks: Specification data are reference values. Terminal No.

Wire color

29

G/R

42

B

Item

Judgement standard

Condition

Secondary speed sensor

When driving (D position, 20 km/h), the pulse measurement by using the pulse measurement function of CONSULT-II. I CONSULT-II cable connected to data link connector. I This inspection cannot be measured by circuit tester.

Throttle position sensor (Ground)

—

Approx. 600 Hz

—

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0038S02

Check items (Possible cause)

: VEH SPD SEN/CIR AT : P0720

TCM does not receive the proper voltage signal from the sensor.

I Harness or connectors (The sensor circuit is open or shorted.) I Secondary speed sensor

: MI Code No. 0720

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0038S03

SAT651J

CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated.

AT-62

DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Description (Cont’d)

With CONSULT-II 1) 2)

SAT971J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 12 consecutive seconds. THRTL POS SEN: More than 1.3V Selector lever: D position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-65. With GST

Follow the procedure “With CONSULT-II”.

SAT654J

AT-63

DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Wiring Diagram — AT — VSSA/T

Wiring Diagram — AT — VSSA/T SECONDARY SPEED SENSOR

NCAT0201

: Detectable line for DTC : Non-detectable line for DTC

TCM (TRANSMISSION CONTROL MODULE)

ECM

YAT205

AT-64

DTC P0720 VEHICLE SPEED SENSOR CVT (SECONDARY SPEED SENSOR) Diagnostic Procedure

Diagnostic Procedure 1

NCAT0039

CHECK SECONDARY SPEED SENSOR

Refer to “Component Inspection” AT-65. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Repair or replace secondary speed sensor.

2

CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II

1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “VEHICLE SPEED” while driving. Check the value changes according to driving speed. OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM, ECM and secondary speed sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-62. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

Component Inspection SECONDARY SPEED SENSOR 1. 2.

NCAT0040 NCAT0040S01

Jacking up the vehicle. Check pulse by using the pulse measurement function of CONSULT-II when front wheel rotating. I CONSULT-II cable connected to data link connector. At front wheel rotating (D position, 20 km/h): Approx. 600 Hz

CONSULT-II

To data link connector

DDL

PULSE

NAT315

AT-65

DTC P0725 ENGINE SPEED SIGNAL Description

Description

NCAT0041

The engine speed signal is sent from the ECM to the TCM.

TCM TERMINALS AND REFERENCE VALUE

NCAT0041S01

Remarks: Specification data are reference values. Terminal No.

Wire color

39

L/OR

Item

Judgement standard

Condition

Engine speed signal

When engine runs at idle speed.

0.5 - 1.5V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0041S02

Check item (Possible cause)

: ENGINE SPEED SIG : P0725

TCM does not receive the proper voltage I Harness or connectors signal from ECM. (The sensor circuit is open or shorted.)

: MI Code No. 0725

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0041S03

SAT651J

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

SAT654J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 10 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position If the check result is “NG”, go to “Diagnostic Procedure”, AT-68. With GST

Follow the procedure “With CONSULT-II”.

AT-66

DTC P0725 ENGINE SPEED SIGNAL Wiring Diagram — AT — ENGSS

Wiring Diagram — AT — ENGSS

NCAT0202

ECM

: Detectable line for DTC : Non-detectable line for DTC

TCM (TRANSMISSION CONTROL MODULE)

YAT206

AT-67

DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure

Diagnostic Procedure 1

NCAT0042

CHECK DTC WITH ECM

Perform diagnostic test mode II (self-diagnostic results) for engine control. Check ignition signal circuit condition. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Check ignition signal circuit for engine control. Refer to EC section (IGNITION SIGNAL).

2

CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II

1. Start engine. 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position. OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM and ECM I Resistor and ignition coil Refer to EC section (IGNITION SIGNAL).

3

CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II

1. Start engine. 2. Check voltage between TCM terminal 39 and ground. Voltage (Idle speed): 0.5 - 1.5V

SAT424JA

OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM and ECM I Resistor and ignition coil Refer to EC section (IGNITION SIGNAL).

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-66. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-68

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description

Description

NCAT0055

The torque converter clutch solenoid valve is activated, by the TCM in response to signals sent from the vehicle speed and throttle position sensors. Lock-up piston operation will then be controlled. Lock-up operation, however, is prohibited when CVT fluid temperature is too low. When the accelerator pedal is depressed (less than 2/8) in lock-up condition, the engine speed should not change abruptly. If there is a big jump in engine speed, there is no lock-up.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0055S01 Remarks: Specification data are reference values. Monitor item Torque converter clutch solenoid valve duty

Condition

Specification

Lock-up “OFF” " Lock-up “ON”

Approximately 4% " Approximately 94%

TCM TERMINALS AND REFERENCE VALUE

NCAT0055S02

Remarks: Specification data are reference values. Terminal No.

3

Wire color

GY/R

Item

Judgement standard

Condition

Torque converter clutch solenoid valve

When CVT performs lock-up.

Approx. 12.0V

When CVT does not perform lockup.

Approx. 0V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0055S03

Check items (Possible cause)

: TCC SOLENOID/CIRC : P0740

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

I Harness or connectors (The solenoid circuit is open or shorted.) I T/C clutch solenoid valve

: MI Code No. 0740

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0055S04 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. SAT651J

AT-69

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description (Cont’d)

With CONSULT-II 1) 2)

Turn ignition switch “ON”. Select “DATA MONITOR” mode for “ENGINE” with CONSULT-II and wait at least 10 seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-72. With GST

Follow the procedure “With CONSULT-II”. SAT654J

AT-70

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Wiring Diagram — AT — TCV

Wiring Diagram — AT — TCV

NCAT0207

AT-TCV-01

LU DUTY SOL 3

TCM (TRANSMISSION CONTROL MODULE)

M48

GY/R : Detectable line for DTC : Non-detectable line for DTC

GY/R M53 21 F102 GY/R

GY/R 9

CONTROL VALVE (TORQUE CONVERTER CLUTCH SOLENOID VALVE)

F71

5 4 3 2 1 10 9 8 7 6

6 7 8 9 10 1 2 3 4 5 F102 11 12 13 14 15 16 17 18 19 20 21 22 23 24 W

F71 G

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

M48 W YAT149

AT-71

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Diagnostic Procedure

Diagnostic Procedure 1

NCAT0056

CHECK GROUND CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal 9 and ground. Resistance: 10 - 20Ω OK or NG OK

©

GO TO 2.

NG

©

Replace CVT assembly

2

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check continuity between terminal 9 and TCM harness connector terminal 3. Continuity should exist.

SAT683J

If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. OK or NG OK

©

GO TO 3.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

3

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-69. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-72

DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Component Inspection

Component Inspection

NCAT0057

TORQUE CONVERTER CLUTCH SOLENOID VALVENCAT0057S01 I To torque converter clutch solenoid valve

For removal, refer to AT-116.

Resistance Check I

NCAT0057S0101

Check resistance between two terminals. Solenoid valve

Torque converter clutch solenoid valve

Terminal No.

9

Ground of TCC solenoid valve

Resistance (Approx.) 10 - 16Ω

SAT684J

Operation Check I

NCAT0057S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground of TCC solenoid valve.

To torque converter clutch solenoid valve

SAT685J

AT-73

DTC P0745 LINE PRESSURE SOLENOID VALVE Description

Description

NCAT0061

The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to a signal sent from the TCM. The line pressure duty cycle value is not consistent when the closed throttle position switch is “ON”. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is “OFF”.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0061S01 Remarks: Specification data are reference values. Monitor item

Line pressure solenoid valve duty

Condition

Specification

Small throttle opening (Low line pressure) " Large throttle opening (High line pressure)

Approximately 4% " Approximately 94%

NOTE: The line pressure duty cycle value is not consistent when the closed throttle position switch is “ON”. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is “OFF”.

TCM TERMINALS AND REFERENCE VALUE

NCAT0061S02

Remarks: Specification data are reference values. Terminal No.

1

2

Wire color

Item

OR/L

Line pressure solenoid valve

P/B

Judgement standard

Condition When releasing accelerator pedal after warming up engine.

Approx. 2.8V

When depressing accelerator pedal Approx. 1.4V fully after warming up engine. When releasing accelerator pedal after warming up engine.

Line pressure solenoid valve (with dropping resistor)

Approx. 11.0V

When depressing accelerator pedal Approx. 4.0V fully after warming up engine.

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0061S03

Check items (Possible cause)

: L/PRESS SOL/CIRC : P0745

TCM detects an improper voltage drop when it tries to operate the solenoid valve.

: MI Code No. 0745

AT-74

I Harness or connectors (The solenoid circuit is open or shorted.) I Line pressure solenoid valve

DTC P0745 LINE PRESSURE SOLENOID VALVE Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0061S04 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. SAT651J

With CONSULT-II 1) 2)

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Depress accelerator pedal completely and wait at least 5 seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-77. With GST

Follow the procedure “With CONSULT-II”. SAT654J

AT-75

DTC P0745 LINE PRESSURE SOLENOID VALVE Wiring Diagram — AT — LPSV

Wiring Diagram — AT — LPSV TCM (TRANSMISSION CONTROL MODULE)

PL DUTY SOL (DR) 2

PL DUTY SOL 1

P/B

OR/L

P/B 20

F102

P/B

AT-LPSV-01

M48

OR/L M53

NCAT0209

: Detectable line for DTC

22

: Non-detectable line for DTC

OR/L

P/B 2 DROPPING RESISTOR

F86 1 OR/L

OR/L 8 CONTROL VALVE (LINE PRESSURE SOLENOID VALVE)

F71

1 2

F86 GY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

5 4 3 2 1 10 9 8 7 6

F71 G

1 2 3 4 5 6 7 8 9 10 F102 11 12 13 14 15 16 17 18 19 20 21 22 23 24 W

M48 W YAT150

AT-76

DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure

Diagnostic Procedure 1

NCAT0062

CHECK GROUND CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal 8 and ground. Resistance: 2.5 - 5Ω OK or NG OK

©

GO TO 2.

NG

©

Check the following items: I Line pressure solenoid valve Refer to “Component Inspection”, AT-78. I Harness of terminal cord assembly for short or open

2

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 8 and TCM harness connector terminal 2. Resistance: 11.2 - 12.8Ω OK or NG OK

©

GO TO 3.

NG

©

Check the following items: I Dropping resistor Refer to “Component Inspection”, AT-78. I Harness for short or open between TCM terminal 2 and terminal cord assembly (Main harness)

3

CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to “OFF” position. 2. Check continuity between terminal 8 and TCM harness connector terminal 1. Continuity should exist. If OK, check harness for short to ground and short to power. 3. Reinstall any part removed. OK or NG OK

©

GO TO 4.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-75. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-77

DTC P0745 LINE PRESSURE SOLENOID VALVE Component Inspection

Component Inspection

=NCAT0063

LINE PRESSURE SOLENOID VALVE I

Resistance Check I To line pressure solenoid valve

NCAT0063S01

For removal, refer to AT-116. NCAT0063S0101

Check resistance between two terminals. Solenoid valve

Line pressure solenoid valve

Terminal No.

8

Ground of line pressure solenoid valve

Resistance (Approx.) 2.5 - 5Ω

SAT686J

Operation Check I

NCAT0063S0102

Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground of line pressure solenoid valve.

To line pressure solenoid valve

SAT687J

DROPPING RESISTOR I

Check resistance between two terminals. Resistance: 11.2 - 12.8Ω

SAT444J

AT-78

NCAT0063S02

DTC P1705 THROTTLE POSITION SENSOR Description

Description

Throttle position sensor and throttle position switch

I I

SAT413J

NCAT0070

Throttle position sensor The throttle position sensor detects the throttle valve position and sends a signal to the TCM. Throttle position switch Consists of a wide open throttle position switch and a closed throttle position switch. The wide open throttle position switch sends a signal to the TCM when the throttle valve is open at least 1/2 of the full throttle position. The closed throttle position switch sends a signal to the TCM when the throttle valve is fully closed.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0070S01 Remarks: Specification data are reference values. Monitor item

Condition

Specification

Fully-closed throttle

Approximately 0.5V

Fully-open throttle

Approximately 4V

Throttle position sensor

TCM TERMINALS AND REFERENCE VALUE

NCAT0070S02

Remarks: Specification data are reference values. Terminal No.

16

17

32

Wire color

Item

Y

Closed throttle position switch (in throttle position switch)

LG

G

When releasing accelerator pedal after warming up engine.

When depressing accelerator pedal more than half-way after warming Battery voltage up engine.

Throttle position sensor (Power source)

GY

Throttle position sensor

42

B

Ground (Throttle position sensor)

Battery voltage

When depressing accelerator pedal Approx. 0V after warming up engine.

Wide open throttle position switch (in throttle position switch)

41

Judgement standard

Condition

When releasing accelerator pedal after warming up engine.

Approx. 0V

When turning ignition switch to “ON”.

4.5 - 5.5V

When turning ignition switch to “OFF”.

Approx. 0V

Fully-closed throttle: When depressing accelerator pedal Approximately 0.3V slowly after warming up engine. (Voltage rises gradually in Fully-open throttle: response to throttle position.) Approximately 3V —

AT-79

—

DTC P1705 THROTTLE POSITION SENSOR Description (Cont’d)

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0070S03

Check items (Possible cause)

: TP SEN/CIRC A/T : P1705

I TCM receives an excessively low or high voltage from the sensor. I I

Harness or connectors (The sensor circuit is open or shorted.) Throttle position sensor Throttle position switch

: MI Code No. 1705

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0070S04

SAT651J

CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

Acceleratr pedal condition

THRTL POS SEN

CLOSED THL/SW

W/O THRL/P⋅SW

Fully released

Less than 0.5V

ON

OFF

Partially depressed

0.5 - 1.9V

OFF

OFF

Fully depressed

1.9 - 4.0V

OFF

ON

SAT971J

3) 4)

SAT654J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Check the following.

If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-82. If the check result is OK, go to following step. Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 5 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POSI SEN: Approximately 3V or less Selector lever: D position If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-82. With GST

Follow the procedure “With CONSULT-II”.

AT-80

DTC P1705 THROTTLE POSITION SENSOR Wiring Diagram — AT — TPS

Wiring Diagram — AT — TPS

NCAT0212

YAT252

AT-81

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure

Diagnostic Procedure 1

NCAT0071

CHECK DTC WITH ECM

Perform diagnostic test mode II (self-diagnostic results) for engine control. Refer to EC section [“Malfunction Indicator (MI)”, “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION”]. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Check throttle position sensor circuit for engine control. Refer to EC section (“DTC P0120 THROTTLE POSITION SENSOR”).

2

CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “THRTL POS SEN”. Voltage: Fully-closed throttle: Approximately 0.5V Fully-open throttle: Approximately 4V OK or NG OK

©

GO TO 4.

NG

©

Check harness for short or open between ECM and TCM regarding throttle position sensor circuit. (Main harness)

3

CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 41 and 42 while accelerator pedal is depressed slowly. Voltage: Fully-closed throttle valve: Approximately 0.5V Fully-open throttle valve: Approximately 4V (Voltage rises gradually in response to throttle position)

SAT453J

OK or NG OK

©

GO TO 5.

NG

©

Check harness for short or open between ECM and TCM regarding throttle position sensor circuit. (Main harness)

AT-82

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)

4

CHECK THROTTLE POSITION SWITCH CIRCUIT (With CONSULT-II) With CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.

Accelerator pedal condition

Data monitor CLOSED THL/SW

W/O THRL/P-SW

Released

ON

OFF

Fully depressed

OFF

ON

OK or NG

MTLB0011

OK

©

GO TO 6.

NG

©

Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)

AT-83

DTC P1705 THROTTLE POSITION SENSOR Diagnostic Procedure (Cont’d)

5

CHECK THROTTLE POSITION SWITCH CIRCUIT (Without CONSULT-II) Without CONSULT-II

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 16, 17 and ground while depressing, and releasing accelerator pedal slowly. (After warming up engine) Voltage

Accelerator pedal condition

Terminal No. 16

Terminal No. 17

Released

Battery voltage

1V or less

Fully depressed

1V or less

Battery voltage MTBL0137

SAT454J

OK or NG OK

©

GO TO 6.

NG

©

Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)

6

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-80. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-84

DTC P1705 THROTTLE POSITION SENSOR Component Inspection

Component Inspection

=NCAT0072

THROTTLE POSITION SWITCH Closed Throttle Position Switch (Idle position) I

Throttle position switch harness connector

SAT688J

I

Throttle position switch harness connector

NCAT0072S0101

Check continuity between terminals 5 and 6. Accelerator pedal condition

Continuity

Released

Yes

Depressed

No

To adjust closed throttle position switch, refer to EC section (“Basic Inspection”, “TROUBLE DIAGNOSIS — Basic Inspection”).

Wide Open Throttle Position Switch I

NCAT0072S01

NCAT0072S0102

Check continuity between terminals 5 and 4. Accelerator pedal condition

Continuity

Released

No

Depressed

Yes

SAT689J

AT-85

DTC P1777 STEP MOTOR — CIRCUIT Description

Description I

NCAT0224

The step motor is ON/OFF of 4 aspects changes according to the signal from TCM. As a result, the flow of line pressure to primary pulley is changed and pulley ratio is controlled.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0224S01 Remarks: Specification data are reference values. Monitor item Step motor

Condition

Specification

The vehicle runs a safe condition and press/depress accelerator pedal.

ON/OFF

TCM TERMINALS AND REFERENCE VALUE

NCAT0224S02

Remarks: Specification data are reference values. Terminal No.

Wire color

11

PU

12

L/W

20

L/Y

21

P/L

Item

Step motor

Judgement standard

Condition

30.0 msec Within 2 seconds after key switch “ON”, the time measurement by using the pulse width measurement function (Hi level) of CON10.0 msec SULT-II. 30.0 msec I CONSULT-II cable connect to data link connector. I This inspection cannot be measured by circuit tester. 10.0 msec

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0224S03

Check items (Possible cause)

: STEP MOTOR/CIRC : P1777

When in operating step motor ON and OFF, there is no proper change in the voltage of the terminal TCM which corresponds to it.

: MI Code No. 1777

AT-86

I Harness or connectors (The step motor circuit is open or shorted.) I Step motor

DTC P1777 STEP MOTOR — CIRCUIT Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0224S04

SAT651J

CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

SAT654J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Drive vehicle for at least 5 consecutive seconds. If the check result is “NG”, go to “Diagnostic Procedure”, AT-89. With GST

Follow the procedure “With CONSULT-II”.

AT-87

DTC P1777 STEP MOTOR — CIRCUIT Wiring Diagram — AT — STM

Wiring Diagram — AT — STM

NCAT0225

TCM (TRANSMISSION CONTROL MODULE) : Detectable line for DTC : Non-detectable line for DTC

CONTROL VALVE (STEP MOTOR)

YAT208

AT-88

DTC P1777 STEP MOTOR — CIRCUIT Diagnostic Procedure

Diagnostic Procedure 1 1. 2. 3. 4. 5. 6.

NCAT0226

CHECK POWER SOURCE CIRCUIT Turn ignition switch to “ON” position. Check “SELF-DIAGNOSIS” with CONSULT-II. If “CVT SAFE FUNCTION” activate, refer to “CVT SAFE FUNCTION” AT-99. Turn ignition switch to “OFF” position. Disconnect TCM harness connector. Check continuity between terminal 2, 3, 4, 5 and TCM harness connector terminal 11, 12, 20, 21. Continuity should exist.

Step motor connector

SAT655J

If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. OK or NG OK

©

GO TO 2.

NG

©

Repair open circuit or short to ground or short to power in harness or connectors.

2

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-91. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-89

DTC P1777 STEP MOTOR — CIRCUIT Component Inspection

Component Inspection

=NCAT0227

STEP MOTOR Resistance Check CVT fluid pressure sensor connector

I

NCAT0227S01 NCAT0227S0101

Check resistance between terminals. Control valve

Terminal No.

Resistance (Approx.)

2 and 3 28Ω 4 and 5 SAT690J

2 and ground Step motor 3 and ground 14Ω 4 and ground 5 and ground

AT-90

DTC P1778 STEP MOTOR — FUNCTION Description

Description I

I I

NCAT0228

The step motor is ON/OFF of 4 aspects changes according to the signal from TCM. As a result, the flow of line pressure to primary pulley is changed and pulley ratio is controlled. This diagnosis item detects when electrical system is OK but, mechanical system is NG. This diagnosis item detects when the state that the changing the speed mechanism in unit does not operate normally.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0228S01 It is monitoring whether “CVT RATIO: 2.32 - 0.47” changes similarly to “PLY CONT STEP: 3 - 200” by DATA MONITOR mode.

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0228S03

Check items (Possible cause)

: STEP MOTOR/FNCTN : P1778

When not changing the speed according to the instruction of TCM.

I Step motor

: MI Code No. 1778

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0228S04

SAT651J

CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. I Before start “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”, confirm “Hi” or “Mid” or “Low” fixation by “I/P PULLY SPD” and “VHCL SPEED SE” on “DATA MONITOR MODE”. I If hi-geared fixation, go to diagnostic procedure soon. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1)

Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II.

SAT971J

AT-91

DTC P1778 STEP MOTOR — FUNCTION Description (Cont’d)

2)

3) 4)

SAT654J

Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid) Select “ENGINE” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 30 consecutive seconds. TEST START FROM 0 km/h (0 MPH) CONSTANT ACCELERATION: Keep 30 sec or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-93. With GST

Follow the procedure “With CONSULT-II”.

AT-92

DTC P1778 STEP MOTOR — FUNCTION Diagnostic Procedure

Diagnostic Procedure 1

CHECK STEP MOTOR

I It is monitoring whether “CVT ratio: 2.32 - 0.47” changes similarly to “PLY CONT STEP: -3 - 200” by DATA MONITOR mode. I If no CONSULT-II, inspect the engine speed (rise and descend) about vehicle speed and throttle opening angle, and check shift change. OK or NG OK

©

INSPECTION END

NG

©

Replace CVT assembly.

AT-93

NCAT0230

DTC P1791 CVT FLUID PRESSURE SENSOR Description

Description I

NCAT0232

The CVT fluid pressure sensor detects line pressure of CVT, and sends TCM the signal.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NCAT0232S01 Remarks: Specification data are reference values. Monitor item

CVT fluid pressure sensor

Condition

Specification

Throttle valve fully closed (PL Duty: 4%) " Throttle valve fully depressed (PL Duty: 94%)

Approx. 1.0 V " Approx. 4.0 V

TCM TERMINALS AND REFERENCE VALUE

NCAT0232S02

Remarks: Specification data are reference values. Terminal No.

Wire color

37

Item

Judgement standard

Condition

When engine runs at idle speed.

Approx. 1.0 V

When engine runs at stall speed.

Approx. 4.0V

W/G CVT fluid pressure sensor

42

B

—

—

46

P/L

—

4.5 - 5.5 V

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

NCAT0232S03

Check items (Possible cause)

: LINE PRESS SEN : P1791

TCM receives an excessively low or high voltage from the step motor.

: MI Code No. 1791

AT-94

I Harness or connectors (The sensor circuit is open or shorted.) I CVT fluid pressure sensor

DTC P1791 CVT FLUID PRESSURE SENSOR Description (Cont’d)

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0232S04

SAT651J

CAUTION: I Always drive vehicle at a safe speed. I Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) 2)

SAT971J

3) 4)

SAT654J

Turn ignition switch “ON” and select “DATA MONITOR” mode for “CVT” with CONSULT-II. Make sure that output voltage of CVT fluid temperature snesor is within the range below. FLUID TEMP SEN: 0.5 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: 1.3V Selector lever: D position ENG SPEED: 450 rpm or more If the check result is NG, go to “Diagnostic Procedure”, AT-97. With GST

Follow the procedure “With CONSULT-II”.

AT-95

DTC P1791 CVT FLUID PRESSURE SENSOR Wiring Diagram — AT — FPS

Wiring Diagram — AT — FPS CONTROL VALVE (CVT FLUID PRESSURE SENSOR)

NCAT0233

: Detectable line for DTC : Non-detectable line for DTC

TCM (TRANSMISSION CONTROL MODULE)

ECM

YAT209

AT-96

DTC P1791 CVT FLUID PRESSURE SENSOR Diagnostic Procedure

Diagnostic Procedure 1

NCAT0234

CHECK PRESSURE SENSOR

Refer to “Component Inspection”, AT-98. OK or NG OK (With CONSULT-II)

©

GO TO 2.

OK (Without CONSULT-II)

©

GO TO 3.

NG

©

Repair or replace pressure sensor.

2

CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II

1. Start engine. 2. Select “ECU Input Item Parameter List” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out the value of “LINE PRES SEN” while driving. I Throttle valve fully closed (PL Duty: 4%): Approx. 1.0V I Throttle valve fully depressed (PL Duty: 94%): Approx. 4.0V OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM, ECM and CVT fluid pressure sensor (Main harness) I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

3

CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II

Refer to “Component Inspection”, AT-98. OK or NG OK

©

GO TO 4.

NG

©

Check the following items: I Harness for short or open between TCM, ECM and CVT fluid pressure sensor (Main harness). I Ground circuit for ECM Refer to EC section (“TROUBLE DIAGNOSIS FOR POWER SUPPLY”).

4

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-95. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-97

DTC P1791 CVT FLUID PRESSURE SENSOR Component Inspection

Component Inspection

=NCAT0235

CVT FLUID PRESSURE SENSOR CVT fluid pressure sensor connector

I I

NCAT0235S01

Start engine. Check voltage between terminals 1 and 6, 6 and 10. Terminal No.

Voltage

1

6

Approx. 0.5 - 4.5V

6

10

Approx. 4.5 - 5.5V

SAT691J

AT-98

CVT SAFE FUNCTION Description

Description “CVT SAFE FUNCTION” is function to protect CVT.

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code

Malfunction is detected when ...

Check items (Possible cause)

: CVT SAFE FUNCTION TCM is malfunctioning

TCM

: 10th judgement flicker

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE With CONSULT-II 1) 2) 3)

Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed. Without CONSULT-II

SAT651J

1) 2)

Start engine. Perform self-diagnosis. Refer to SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II), AT-25.

SAT971J

Light

Shade

SAT455FA

AT-99

CVT SAFE FUNCTION Diagnostic Procedure

Diagnostic Procedure 1

CHECK INPUT SIGNAL (With CONSULT-II)

1. Turn ignition switch to “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Touch “ERASE”. Perform “DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE”. See previous page. Is the “CVT SAFE FUNCTION” displayed again? YES

©

Replace TCM

NO

©

INSPECTION END

AT-100

CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description

Description

NCAT0239

The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the CVT.

SAT574J

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONTROL UNIT (RAM) : CONTROL UNIT (ROM)

Malfunction is detected when ... TCM memory (RAM) or (ROM) is malfunctioning.

NCAT0239S01

Check item (Possible cause)

TCM

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0239S02 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) SAT651J

2) 3)

Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed.

SAT971J

AT-101

CONTROL UNIT (RAM), CONTROL UNIT (ROM) Diagnostic Procedure

Diagnostic Procedure 1

CHECK DTC With CONSULT-II

1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Touch “ERASE”. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONTROL UNIT (RAM) or CONTROL UNIT (ROM)” displayed again? Yes

©

Replace TCM.

No

©

INSPECTION END

AT-102

=NCAT0240

CONTROL UNIT (EEPROM) Description

Description

NCAT0241

The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the CVT.

SAT574J

ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONT UNIT (EEPROM)

Malfunction is detected when ... TCM memory (EEPROM) is malfunctioning.

NCAT0241S01

Check item (Possible cause) TCM

DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NCAT0241S02 NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) SAT651J

2) 3)

Turn ignition switch “ON” and select “DATA MONITOR” mode for CVT with CONSULT-II. Start engine. Run engine for at least 2 seconds at idle speed.

SAT971J

AT-103

CONTROL UNIT (EEPROM) Diagnostic Procedure

Diagnostic Procedure 1

CHECK DTC With CONSULT-II

1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for CVT with CONSULT-II. 2. Move selector lever to “R” position. 3. Depress accelerator pedal (Full throttle position). 4. Touch “ERASE”. 5. Turn ignition switch “OFF” position for 10 seconds. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONT UNIT (EEPROM)” displayed again? Yes

©

Replace TCM.

No

©

INSPECTION END

AT-104

=NCAT0242

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch

PNP Switch, Stop Lamp Switch and Throttle Position Switch

NAAT0204

SYMPTOM: CVT or SPORT indicator lamp does not come on in TCM selfdiagnostic procedure even the lamp circuit is good.

DESCRIPTION I I I I

NAT0204S01

PNP switch The PNP switch assemble includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM. Stop lamp switch Detects the stop lamp switch position (ON or OFF) and sends a signal to the TCM Throttle position switch. Consists of a wide open throttle position switch and a closed throttle position switch. The wide open throttle position switch sends a signal to the TCM when the throttle valve is open at least 1/2 of the full throttle position. The closed throttle position switch sends a signal to the TCM when the throttle valve is fully closed.

AT-105

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)

1

CHECK PNP SWITCH CIRCUIT (With CONSULT-II)

With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.

SAT651J

3. Read out “P/N”, “R”, “D” and “L” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. OK or NG OK

©

GO TO 3.

NG

©

Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)

2

CHECK PNP SWITCH CIRCUIT (Without CONSULT-II)

With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 27, 34, 35, 36 and ground while moving selector lever through each position. Voltage: B: Battery voltage 0: 0V Lever position P,N R D L

36 B 0 0 0

Terminal No. 35 34 0 0 B 0 0 B 0 0

27 0 0 0 B MTBL0312

OK or NG OK

©

GO TO 3.

NG

©

Check the following items: I PNP switch Refer to “Component Inspection”, AT-53. I Harness for short or open between ignition switch and PNP switch (Main harness) I Harness for short or open between PNP switch and TCM (Main harness) I Ignition switch and fuse Refer to EL section (“POWER SUPPLY ROUTING”). I Diode (P, N positions)

AT-106

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)

3

CHECK PNP SWITCH CIRCUIT (With CONSULT-II)

With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II.

SAT651J

3. Read out “BRAKE SW” moving brake pedal to each position. Check the signal of the brake pedal is indicated properly. OK or NG OK

©

GO TO 5.

NG

©

Check the following items: I Harness for short or open between fuse block and PNP switch harness terminal 3 I Fuse I Ignition switch (Refer to EL section.)

4

CHECK STOP LAMP SWITCH CIRCUIT (Without CONSULT-II)

1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between stop lamp switch harness terminal 1 and ground. Refer to “Wiring Diagram — CVT — MAIN”, AT-45.

Stop lamp switch LHD models RHD models

SAT733J

Does battery voltage exist? OK

©

GO TO 5.

NG

©

Check the following items: I Harness for short or open between battery and stop lamp switch harness terminal 1 I Fuse I Ignition switch (Refer to EL section.)

AT-107

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)

5

CHECK THROTTLE POSITION SWITCH CIRCUIT (With CONSULT-II)

With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “ECU INPUT SIGNALS” in “DATA MONITOR” mode for “CVT” with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly.

Accelerator pedal condition

Data monitor CLOSED THL/SW

W/O THRL/P-SW

Released

ON

OFF

Fully depressed

OFF

ON MTLB0011

OK or NG OK

©

GO TO 7.

NG

©

Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)

AT-108

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS PNP Switch, Stop Lamp Switch and Throttle Position Switch (Cont’d)

6

CHECK THROTTLE POSITION SWITCH CIRCUIT (Without CONSULT-II)

Without CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM terminals 16, 17 and ground while depressing, and releasing accelerator pedal slowly. (After warming up engine) Voltage

Accelerator pedal condition

Terminal No. 16

Terminal No. 17

Released

Battery voltage

1V or less

Fully depressed

1V or less

Battery voltage MTBL0137

SAT454J

OK or NG OK

©

GO TO 7.

NG

©

Check the following items: I Throttle position switch — Refer to “Components Inspection”, AT-85. I Harness for short or open between ignition switch and throttle position switch (Main harness) I Harness for short or open between throttle position switch and TCM (Main harness)

7

CHECK DTC

Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-103. OK or NG OK

©

INSPECTION END

NG

©

1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.

AT-109

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC

Wiring Diagram — AT — NONDTC MODELS BEFORE VIN - P11U0548750 BATTERY

NCAT0237

IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

Refer to EL-POWER.

TCM (TRANSMISSION CONTROL MODULE)

Detectable line for DTC Non-detectable line for DTC Hyper CVT models Hyper CVT M6 models SPORT indicator lamp CVT warning lamp

UNIFIED METER CONTROL UNIT

COMBINATION METER

INDICATOR CONTROL UNIT

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YAT155

AT-110

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)

MODELS AFTER VIN - P11U0548750

YAT253

AT-111

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)

YAT254

AT-112

TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS Wiring Diagram — AT — NONDTC (Cont’d)

YAT255

AT-113

ON-VEHICLE SERVICE Control Cable Adjustment

Control Cable Adjustment

Control cable

Lock nut

Manual shaft SAT658J

Park/Neutral Position (PNP) Switch Adjustment

Pin

NCAT0112

PNP switch

Manual shaft (N range)

NCAT0111

Move selector lever from the “P” position to the “L” position. You should be able to feel the detents in each position. If the detents cannot be felt or if the pointer indicating the position is improperly aligned, the control cable needs adjustment. 1. Place selector lever in “P” position. 2. Loosen control cable lock nut and place manual shaft in “P” position. CAUTION: Turn wheels more than 1/4 rotations and apply the park lock. 3. Tighten control cable lock nut. : 12 - 14 N⋅m (1.2 - 1.5 kg-m, 9 - 10 ft-lb) 4. Move selector lever from “P” to “L” position again. Make sure that selector lever moves smoothly. 5. Apply grease to contacting areas of selector lever and control cable. Install any part removed.

1. 2. 3.

Remove control cable end from manual shaft. Set manual shaft in “N” position. Loosen PNP switch fixing bolts.

4. a. b.

Use a 4 mm (0.157 in) pin for this adjustment. Insert the pin straight into the manual shaft adjustment hole. Rotate PNP switch until the pin can also be inserted straight into hole in PNP switch. Tighten PNP switch fixing bolts. : 4.9 - 6.8 N⋅m (0.5 - 0.7 kg-m, 44 - 60 in-lb) Remove pin from adjustment hole after adjusting PNP switch. Reinstall any part removed. Adjust control cable. Refer to “Control Cable Adjustment”. Check continuity of PNP switch. Refer to AT-53.

SAT659J

5. 6. 7. 8. 9.

Differential Side Oil Seal Replacement 1. 2.

NCAT0113

Remove drive shaft assemblies. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). Remove oil seals.

Oil seal

SAT660J

AT-114

ON-VEHICLE SERVICE Differential Side Oil Seal Replacement (Cont’d)

3. I I

Install oil seals. Apply CVT fluid to oil seal surface before installing. Install oil seals so that dimensions “A” and “B” are within specifications. Unit: mm (in)

Left side

Right side SAT661J

4.

A

B

5.5 - 6.5 (0.217 - 0.256)

−0.5 to 0.5 (−0.020 to 0.020)

Reinstall any part removed.

AT-115

REMOVAL AND INSTALLATION Removal

Removal

SAT664J

NCAT0115

CAUTION: Before separating transaxle from engine, remove the crankshaft position sensor (OBD) from transaxle. Be careful not to damage sensor. 1. Remove battery and bracket. 2. Remove air duct between throttle body and air cleaner. 3. Disconnect control valve harness connector, PNP switch harness connector, secondary speed sensor harness connector, dropping resistor harness connector, primary speed sensor harness connector and body earth harness connector. 4. Remove crankshaft position sensor (OBD) from transaxle. 5. Drain CVT fluid from transaxle. 6. Disconnect control cable from transaxle. 7. Remove exhaust front tube. Refer to FE section (“EXHAUST SYSTEM”). 8. Remove drive shafts. Refer to FA section (“Drive Shaft”, “FRONT AXLE”). 9. Disconnect oil cooler hoses. 10. Remove starter motor from transaxle. Tighten bolts to specified torque. : 41 - 52 N⋅m (4.2 - 5.3 kg-m, 30 - 38 ft-lb) 11. Support transaxle with a jack. 12. Remove center member. I Tighten center member fixing bolts to specified torque, Refer to EM section (“ENGINE REMOVAL”). 13. Remove rear plate cover. 14. Remove torque converter bolts. Rotate crankshaft to gain access to securing bolts. 15. Support engine with a jack. 16. Remove transaxle mount bolt. Refer to EM section (“ENGINE REMOVAL”). 17. Remove oil cooler tube (outlet side). 18. Remove transaxle.

Inspection I

NCAT0236

When connecting torque converter to transaxle, measure distance “A” to be certain that they are correctly assembled. Distance “A”: 15.9 mm (0.626 in) or more

SAT665J

AT-116

REMOVAL AND INSTALLATION Installation : Transaxle to engine

Installation

: Engine to transaxle

1.

SAT666J

NCAT0116

Tighten bolts fixing transaxle. Bolt No.

Tightening torque N⋅m (kg-m, ft-lb)

Bolt length “” mm (in)

1

70 - 79 (7.1 - 8.1, 51 - 59)

40 (1.57)

2

31 - 36 (3.1 - 3.7, 23 - 26)

35 (1.38)

3

31 - 36 (3.1 - 3.7, 23 - 26)

47 (1.85)

4

70 - 79 (7.1 - 8.1, 52 - 58)

65 (2.56)

2. I

Install torque converter to drive plate. With converter installed, rotate crankshaft several turns to check that transaxle rotates freely without binding.

3. 4. 5. 6. 7.

Reinstall any part removed. Adjust control cable. Refer to AT-114. Check continuity of PNP switch. Refer to AT-53. Refill transaxle with CVT fluid and check fluid level. Move selector lever through all positions to be sure that transaxle operates correctly. With parking brake applied, idle engine. A slight shock should be felt through the hand gripping the selector each time the transaxle is shifted. Perform road test. Refer to AT-36.

8. SAT638A

AT-117

REMOVAL AND INSTALLATION Air Breather Hose

Air Breather Hose SR20DE Air breather hose Engine harness

Air duct Clip Control cable Air conditioner tube

Paint mark upside More than 17 mm insert Front

NAT312

CVT Fluid Cooler (Hyper CVT-M6) SEC. 310

Radiator core support (lower) Hose

Radiator 4.5 - 5.7 (0.45 - 0.59)

Tube

Bumper retainer Front Radiator shroud Hose Upper bracket

Side member

Lower bracket

CVT fluid hydraulic circuit

Tube

Radiator CVT fluid cooler Fluid cooler 4.5 - 5.7 (0.45 - 0.59)

Hose

4.5 - 5.7 (0.45 - 0.59)

: N·m (kg-m)

NAT313

AT-118

REMOVAL AND INSTALLATION Components

Components SEC. 310⋅311⋅312⋅319

5.0 - 6.8 (0.5 - 0.7, 44 - 60)

5.0 - 6.8 (0.5 - 0.7, 44 - 60) PNP SW

Fluid level gauge

Fluid charging pipe Dropping resistor

Secondary pulley speed sensor 5.0 - 6.8 (0.5 - 0.7, 44 - 60)

4.5 - 5.7 (0.45 - 0.59, 40 - 50) O-ring

Speedometer pinion

5.0 - 6.8 (0.5 - 0.7, 44 - 60)

Differential oil seal O-ring

O-ring

Primary pulley speed sensor

O-ring

40 - 58 (4.0 - 6.0, 30 - 43) Copper washer 4.5 - 5.7 (0.45 - 0.59, 40 - 50)

Differential oil seal

Tube (outlet) 4.5 - 5.7 (0.45 - 0.59, 40 - 50) Oil pump oil seal

Torque converter

Copper washer Input shaft O-ring 40 - 58 (4.0 - 6.0, 30 - 43)

CVT assy Oil pan gasket

Oil pan installation bolt (18)

Tube (inlet)

Gasket

6.9 - 8.8 (0.7 - 0.9, 61 - 78)

Drain bolt 30 - 39 (3.0 - 4.0, 22 - 29) Magnet : N·m (kg-m, in-lb)

4.5 - 5.7 (0.45 - 0.59, 40 - 50)

Oil pan

: N·m (kg-m, ft-lb) : CVT fluid NS-1 NAT311

AT-119

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

General Specifications

NCAT0179

Engine

SR20DE

Automatic transaxle model

RE0F06A

Automatic transaxle assembly

Transaxle gear ratio

Model code number

8E020

D range

Variable

Reverse

1.586

Final drive

5.473

Recommended fluid

Nissan CVT fluid NS-1*1

Fluid capacity

8.1 (7-1/8 Imp qt)

*1: Refer to MA section (“Fluids and Lubricants”, “RECOMMENDED FLUIDS AND LUBRICANTS”). Any other fluid will damage the CVT.

Stall Revolution Engine

NCAT0181

Stall revolution

(SR20DE)

rpm

2,350 - 2,850

Line Pressure

NCAT0182 2

Engine speed rpm

Line pressure MPa (kg/cm , psi) R position

D position

Idle

0.6 (6.1, 87)

Stall

4.1 (42, 595)

L position

Removal and Installation

NCAT0197

Unit: mm (in) Distance between end of converter housing and torque converter

AT-120

15.9 (0.626) or more

FRONT AXLE & FRONT SUSPENSION SECTION

FA

CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Special Service Tools ................................................ 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 FRONT SUSPENSION SYSTEM .................................. 4 ON-VEHICLE SERVICE ................................................ 5 Front Axle and Front Suspension Parts .................... 5 Front Wheel Bearing.................................................. 6 Front Wheel Alignment .............................................. 6 Drive Shaft ................................................................. 8

FRONT AXLE ................................................................ 9 Wheel Hub and Knuckle...........................................11 Drive shaft................................................................ 15 FRONT SUSPENSION ................................................ 26 Coil Spring and Shock Absorber ............................. 28 Third Link and Upper Link ....................................... 29 Transverse Link and Lower Ball Joint ..................... 32 Stabilizer Bar ........................................................... 32 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 34 General Specifications............................................. 34 Inspection and Adjustment ...................................... 35

FA

PRECAUTIONS AND PREPARATION Precautions ●

● GG94310000

SBR500

● ●

When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. When removing each suspension part, check wheel alignment and adjust if necessary. Use Tool when removing or installing brake tubes. Always torque brake lines when installing.

Special Service Tools Tool number Tool name

Description

HT72520000 Ball joint remover

Removing tie-rod outer end and lower ball joint a: 33 (1.30) b: 50 (1.97) v: 11.5 (0.453)

Unit: mm (in)

NT546

HT71780000 Spring compressor

Removing and installing coil spring

NT144

GG94310000 Flare nut torque wrench

Removing and installing brake piping

NT406

a: 10 mm (0.39 in)

KV38106700 KV38106800 Differential side oil seal protector

Installing drive shaft

LH : KV38106700 NT147

RH : KV38106800

IM23600800 Attachment Wheel alignment

Measure wheel alignment a: Screw M24 x 1.5 b: 35 (1.38) dia. c: 65 (2.56) dia. d: 56 (2.20) NT148

e: 12 (0.47)

ST35652000 Strut attachment

Fixing strut assembly

NT145

FA-2

Unit: mm (in)

DRIVE SHAFT

FRONT AXLE AND FRONT SUSPENSION

Symptom

TIRES

ROAD WHEEL

Noise, Vibration Shake Noise Shake Vibration Shimmy Judder Poor quality ride or handling Noise Shake Vibration Shimmy Judder Poor quality ride or handling Noise Shake Shimmy, Judder Poor quality ride or handling X X X X X X X X X X X X X X X X X X X X X X

X X X X X

X: Applicable

FA-3

—

X X

X X X X

X X

X X

X X

X X X

X

X X

X X X

X X

X X X X X

X X

X X

X

X

X

X

X

X

X X X

X X X

X X X

X X X

X

X

X

X

X X X X

Refer to FRONT AXLE AND FRONT SUSPENSION in this chart. Refer to TIRES in this chart. Refer to ROAD WHEEL in this chart. NVH in RA section NVH in BR section NHV in ST section

TIRES ROAD WHEEL REAR AXLE AND REAR SUSPENSION BRAKES STEERING

—

Incorrect tire size

Refer to DRIVE SHAFT in this chart.

—

Non-uniformity

FRONT AXLE AND FRONT SUSPENSION

—

DRIVE SHAFT

—

Deformation or damage

Out-of-round

—

FA-6

Wheel bearing damage

Uneven tire wear

FA-6

Stabilizer bar fatigue

Incorrect air pressure

FA-6 FA-32

Incorrect wheel alignment

FA-5

Spring fatigue Suspension looseness

—

FA-29, FA-29

Parts interference

Bushing or mounting deterioration

FA-29

Shock absorber deformation, damage or deflection

— FA-5

Improper installation, looseness

Imbalance

— FA-21

Possible cause and SUSPECTED PARTS Joint sliding resistance

Reference page

Excessive joint angle

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

Use the chart below to help you find cause of the symptom. If necessary, repair or replace these parts.

X X X X

X X X

X

X

X X X

X

X X X X

X X X X X

X X

X X

X X X X X

X

X

X

X X X X X X X X X

X X X X X X X

X X X X X

X X X

X X X

X X X

X

X

X

X X X X

X X

X X

X X X X X X X

X X

X X X X X

X X X

X X X

FRONT SUSPENSION SYSTEM SEC. 391⋅400⋅401 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Shock absorber mounting insulator Coil spring

88 - 123 (9.0 - 12.5, 65 - 90)

18 - 21 (1.9 - 2.1, 14 - 15)

Upper link bracket

93 - 123 (9.5 - 12.5, 69 - 90)

Front suspension member

61 - 80 (6.3 - 8.1, 45 - 59)

Shock absorber Upper link

Third link

40 - 49 (4.1 - 4.9, 30 - 36)

Stay

Knuckle

98 - 114 (10.0 - 11.6, 73 - 84)

Front

Drive shaft

118 - 147 (12 - 14, 87 - 108)

Transverse link

118 - 147 (12 - 14, 87 - 108)

42 - 49 (4.3 - 4.4, 31 - 36)

Stabilizer bar

42 - 49 (4.3 - 4.9, 31 - 36)

: N·m (kg-m, ft-lb)

NFA028

FA-4

ON-VEHICLE SERVICE Front Axle and Front Suspension Parts Check front axle and front suspension parts for excessive play, cracks, wear or other damage. ● Shake each front wheel to check for excessive play. ● Ensure that new cotter pins are used, and are correctly fitted.

SMA525A

●

Retighten all axle and suspension nuts and bolts to the specified torque. Tightening torque: Refer to FRONT SUSPENSION, FA-26.

●

Check strut (shock absorber) for oil leakage or other damage.

●

Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. If ball joint dust cover is cracked or damaged, replace transverse link.

SMA614

NFA029

SMA113

.

SFA911A SFA911A

FA-5

ON-VEHICLE SERVICE Front Axle and Front Suspension Parts (Cont’d)

Transverse link Brake caliper Dial indicator

Pry bar

Lower ball joint SFA504A

● Check suspension ball joint end play. a. Jack up front of vehicle and set the stands. b. Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. c. Make sure front wheels are straight and brake pedal is depressed. d. Place a pry bar between transverse link and inner rim of road wheel. e. While raising and releasing pry bar, observe maximum dial indicator value. Vertical end play: 0 mm (0 in) f. If ball joint vertical end play exists, remove transverse link and recheck the ball joint. Refer to “FRONT SUSPENSION”, FA-32.

Front Wheel Bearing ● ●

●

Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0.05 mm (0.0020 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, FA-FA11.

SFA912A

Front Wheel Alignment Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Lateral runout

Radial runout SFA975B

PRELIMINARY INSPECTION 1. Check tires for wear and improper inflation. 2. Check wheels for deformation, cracks and other damage. If deformed, remove tire and check wheel runout. Wheel runout: Refer to SDS, FA-35. 3. Check front wheel bearings for looseness. 4. Check front suspension for looseness. 5. Check steering linkage for looseness. 6. Check that front shock absorbers work correctly by using the standard bounce test. 7. Check vehicle posture (Unladen).

FA-6

ON-VEHICLE SERVICE Front Wheel Alignment (Cont’d) CAMBER, CASTER AND KINGPIN INCLINATION Attachment IM23600800

Alignment gauge

SRA096A

Camber, caster and kingpin inclination are preset at factory and cannot be adjusted. 1. Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge. Camber, Caster and Kingpin inclination: Refer to SDS, FA-35. 2. If camber, caster and kingpin inclination are not within specification, inspect front suspension parts. Replace any damaged or worn out parts.

TOE-IN Front

Hub center height

Base line Measuring point

SFA614B

Lines parallel to center line of body

Toe-in = A − B Total toe-in angle = 2 θ SFA234A

Front

Measure toe-in using following procedure: WARNING: ● Always perform following procedure on a flat surface. ● Ensure the way in front of the vehicle is clear before pushing it. 1. Bounce front of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead for about 5 m (16 ft). 3. Put a mark on base line of the tread (rear side) of both tires at the same height as hub center. These are measuring points. 4. Measure distance “A” (rear tires). 5. Push the vehicle slowly forwards to rotate the wheels 180 degrees (1/2 turn). If the wheels have passed 180 degrees, try the above procedure again from the beginning. Never push vehicle backward. 6. Measure distance “B” (front tires). Toe-in (A − B): Refer to SDS, FA-35.

7. Adjust toe-in by varying the length of steering tie-rods. a. Loosen lock nuts.

Lock nut

.

SFA913A

FA-7

ON-VEHICLE SERVICE Front Wheel Alignment (Cont’d) b. Adjust toe-in by screwing tie-rods in and out. Standard length “L”: Refer to ST section (“General Specifications”, “SDS”). c. Tighten lock nuts to specified torque. : 38 - 47 N·m (3.9 - 4.7 kg-m, 28 - 34 ft-lb)

Lock nut

SFA486A

FRONT WHEEL TURNING ANGLE

SFA439B

1. Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest on turning radius gauge properly. 2. Rotate steering wheel all the way right and left; measure turning angle. ● On power steering models, turn steering wheel to full lock and apply force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine at idle. Do not hold the steering wheel at full lock for more than 15 seconds. Wheel turning angle (Full turn): Refer to SDS, FA-35.

Drive Shaft Check for grease leakage or other damage.

.

SFA914A

FA-8

FRONT AXLE MODELS BEFORE VIN - P11U0559000 SEC. 400

Drive shaft Front

98 - 118 (10 - 12, 73 - 87)

Baffle plate Inner grease seal Wheel bearing assembly

Snap ring

Snap ring Knuckle .

18 - 24 (1.8 - 2.4, 13 - 17)

ABS sensor

Wheel bolt

Disc rotor

Outer grease seal Wheel hub Plain washer Wheel bearing lock nut 255 - 333 (26 - 34, 188 - 246) Cotter pin Wheel nut 98 - 118 (10 - 12, 73 - 87)

: N·m (kg-m, ft-lb) : Apply grease

NFA056

FA-9

FRONT AXLE MODELS AFTER VIN - P11U0559000

YFA001

FA-10

FRONT AXLE Wheel Hub and Knuckle REMOVAL CAUTION: Before removing front axle assembly, disconnect ABS wheel sensor from assembly and move it from front axle assembly area. Failure to do so may result in damage to sensor wires and the sensor becoming inoperative. 1. Remove wheel bearing lock nut. SFA897A

2. Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. In this case, suspend the caliper assembly with a wire so as not to stretch the brake hose. Be careful not to depress the brake pedal, to prevent the piston from popping out. Make sure brake hose is not twisted.

SFA898A

3. Separate tie-rod from knuckle with tool. Install stud nut inverted on stud bolt to prevent damage to stud bolt.

HT72520000 SFA899A

4. Remove kingpin cap and securing nut. Separate kingpin from knuckle.

SFA907A

5. Separate drive shaft from knuckle with drift. When removing drive shaft, cover drive shaft boots with waste cloth to prevent damage to them.

Wood SFA900A

FA-11

FRONT AXLE Wheel Hub and Knuckle (Cont’d) ●

Remove ball joint securing nut. Separate from knuckle using Tool (as for tie-rod).

HT72520000 SFA901A

INSTALLATION ● ●

●

Install knuckle with wheel hub. Tighten wheel bearing lock nut. : 236 - 313 N·m (24 - 32 kg-m, 174 - 230 ft-lb) Check that wheel bearings operate smoothly.

SFA906A

●

Check wheel bearing axial end play. Axial end play: 0.05 mm (0.0020 in) or less.

SFA902A

DISASSEMBLY CAUTION: When removing wheel hub or wheel bearing from knuckle, replace wheel bearing assembly (outer race, inner races and grease seals) with a new one.

Suitable tool

Wheel Hub Drive out hub with inner race (outside) from knuckle with a suitable tool. SFA903A

Wheel Bearing Suitable tool

When replacing wheel bearing, replace complete wheel bearing assembly (including inner and outer races). ● Remove bearing inner race (outside), then remove outer grease seal.

SFA654A

FA-12

FRONT AXLE Wheel Hub and Knuckle (Cont’d) ●

Remove inner grease seal from knuckle.

●

Remove inner and outer snap rings.

●

Press out bearing outer race.

SFA904A Suitable tool

SFA685

Suitable tool

SFA905A

INSPECTION Wheel Hub and Knuckle Check wheel hub and knuckle for cracks by using a magnetic exploration or dyeing test.

Snap Ring Check snap ring for wear or cracks. Replace if necessary.

ASSEMBLY Suitable tool Wheel bearing assembly Knuckle Inner snap ring Suitable tool SFA655A

1. Install inner snap ring into groove of knuckle. 2. Press new wheel bearing assembly into knuckle until it contacts snap ring. Maximum load P: 49 kN (5 t, 5.5 US ton, 4.9 lmp ton) CAUTION: ● Do not press inner race of wheel bearing assembly. ● Do not apply oil or grease to mating surfaces of wheel bearing outer race and knuckle. 3. Install outer snap ring into groove of knuckle.

FA-13

FRONT AXLE Wheel Hub and Knuckle (Cont’d) 4. Pack grease seal lip with multi-purpose grease.

Inner side SFA747

5. Install outer grease seal. Maximum load P: 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton) Suitable tool Grease seal

SFA656A

6. Install inner grease seal. Maximum load P: 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)

Suitable tool

Grease seal

Suitable tool SFA657A

7. Press wheel hub into knuckle. Maximum load P: 29 kN (3 ton, 3.3 US ton, 3.0 Imp ton) Be careful not to damage grease seal.

Suitable tool

Wheel bearing assembly

Wheel hub Knuckle

Suitable tool SFA658A

8. Check bearing operation. (1) Add load P with press. Load P: 34.3 - 49.0 kN (3.5 - 5.0 ton, 3.9 - 5.5 US ton, 3.44 - 4.92 Imp ton)

SFA659A

FA-14

FRONT AXLE Wheel Hub and Knuckle (Cont’d) (2) Spin knuckle several turns in both directions. (3) Make sure that wheel bearings operate smoothly.

SFA182A

Drive shaft REMOVAL 1. Remove wheel bearing lock nut. 2. Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. In this case, suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SFA897A

3. Remove tie-rod ball joint. 4. Remove upper knuckle nut. 5. Separate drive shaft from knuckle by lightly tapping it. If it is hard to remove, use a puller. When removing drive shaft, cover drive shaft boots with waste cloth to prevent damage to them. Refer to “FRONT AXLE”, “Wheel Hub and Knuckle”, FA-11.

SFA907A

6. Remove right drive shaft from transaxle. − Models without support bearing −

.

SFA499A

− Models with support bearing −

.

SFA989

FA-15

FRONT AXLE Drive shaft (Cont’d) .

7. Remove left drive shaft from transaxle. − For M/T models − ● Pry off drive shaft from transaxle as shown.

M/T model

.

SFA991

− For CVT models − ● Insert screwdriver into transaxle opening for right drive shaft and strike with a hammer. Be careful not to damage pinion mate shaft and side gear.

CVT model Screwdriver

5 mm (0.20 in)

Pinion mate shaft Side gear Drive shaft

SFA730

INSTALLATION

RH

Transaxle side 1. Install a new oil seal to transaxle. Refer to MT or AT section (“Differential Side Oil Seal Replacement”, “ON-VEHICLE SERVICE”). 2. Set Tool along the inner circumference of oil seal.

KV38106800 SFA482

LH

3. Insert drive shaft into transaxle. Be sure to correctly align the splines and then withdraw Tool. 4. Push drive shaft, then press-fit circular clip on the drive shaft into circular clip groove of side gear. 5. After its insertion, try to pull the flange out of the slide joint by hand. If it pulls out, the circular clip is not properly meshed with the side gear.

KV38106700

SFA483

FA-16

FRONT AXLE Drive shaft (Cont’d) Wheel side ● ●

Install drive shaft into knuckle. Tighten upper knuckle nut and wheel bearing lock nut. Refer to “FRONT AXLE”, “Wheel Hub and Knuckle”, FA-11.

COMPONENTS SEC. 391 Circulair clip: Make sure circular clip is properly meshed with side gear (transaxle side) and joint assembly (wheel side), and will not come out.

Wheel side (90AC type and 98AC type)

Spacer ring ABS rotor

Boot band

Be careful not to damage boots. Use suitable protector or cloth during removal and installation.

All M/T models

Joint assembly

Drive shaft Boot Circular clip B

Boot

Spider assembly

Boot band

Snap ring C Side joint housing Dust shield Circular clip

Transaxle side (GI69 type and GI82 type)

FA-17

NFA054

FRONT AXLE Drive shaft (Cont’d) Circular clip: Make sure circular clip is properly meshed with side gear (transaxle side) and joint assembly (wheel side), and will not come out.

Wheel side (B86 type)

Be careful not to damage boots. Use suitable protector or cloth during removal and installation.

All CVT models

For type with support bearing

25 - 35 (2.6 - 3.6, 19 - 26) 25 - 35 (2.6 - 3.6, 19 - 26) 43 - 58 (4.4 - 5.9, 32 - 43)

Left drive shaft 13 - 19 (1.3 - 1.9, 9 - 14)

: N·m (kg-m, ft-lb)

Transaxle side (D83/T83 type)

Right drive shaft

NFA055 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p

Joint assembly Boot band Boot Circular clip B Drive shaft Boot band Boot Snap ring A

9 p 10 p 11 p 12 p 13 p 14 p 15 p 16 p

Snap ring B Inner race Cage Ball Snap ring C Slide joint housing Dust shield Circular clip A

FA-18

17 p 18 p 19 p 20 p 21 p 22 p 23 p 24 p

Slide joint housing with extention shaft Snap ring E Dust shield Support bearing Support bearing retainer Bracket Snap ring D Dust shield

FRONT AXLE Drive shaft (Cont’d) DISASSEMBLY

Matching mark

TRANSAXLE SIDE (GI69 type and GI82 type) 1. Remove boot bands. 2. Put matching marks on slide joint housing and drive shaft before separating joint assembly. 3. Put matching marks on spider assembly and drive shaft.

SFA963

4. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. 5. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot.

Snap ring SFA612

TRANSAXLE SIDE (D83/T83 type) 1. Remove boot bands. 2. Put matchmarks on slide joint housing and inner race, before separating joint assembly. 3. Remove snap ring “A” with a screwdriver, and pull out slide joint housing.

SFA476

4. Put matchmarks on inner race and drive shaft. 5. Remove snap ring “C”, then remove ball cage, inner race and balls as a unit. 6. Remove snap ring “B”. 7. Draw out boot. Cover drive shaft serrations with tape so as not to damage the boot.

SFA514A

WHEEL SIDE (90AC, 98AC and B86 type) Suitable tool (Sliding hammer)

CAUTION: The joint on the wheel side cannot be disassembled. Before separating joint assembly, put matching marks on drive shaft and joint assembly. ● Separate joint assembly with a suitable tool. Be careful not to damage threads on drive shaft. ● Remove boot bands and draw out boot. ●

Wheel bearing lock nut SFA092A

FA-19

FRONT AXLE Drive shaft (Cont’d) SUPPORT BEARING ●

Remove outer dust shield.

●

Remove inner dust shield.

●

Pry off snap ring.

●

Press support bearing assembly out of drive shaft.

●

Press support bearing out of retainer.

SFA613

SFA691

Suitable tool Snap ring

SFA692

SFA693

Suitable tool

SFA617

FA-20

FRONT AXLE Drive shaft (Cont’d) INSPECTION Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation or other damage.

Drive shaft Replace drive shaft if it is twisted or cracked.

Boot Check boot for fatigue, cracks or wear. Replace boot with new boot bands.

Joint assembly (Transaxle side) GI69 and GI82 type ● Check spider assembly for needle bearing and washer damage. Replace if necessary. ● Check roller surfaces for scratches, wear or other damage. Replace if necessary. ● Check serration for deformation. Replace if necessary. ● Check slide joint housing for any damage. Replace if necessary. D83/T83 type ● Replace joint assembly if it is deformed or damaged.

Joint assembly (Wheel side) Replace joint assembly if it is deformed or damaged.

Support bearing Make sure bearing rolls freely, and is free from noise, cracks, pitting or wear.

Support bearing bracket Check support bearing bracket for cracks with a magnetic exploration or dyeing test.

ASSEMBLY ● ●

After drive shaft has been assembled, ensure that it moves smoothly over its entire range without binding. Use NISSAN GENUINE GREASE or equivalent after every overhaul.

FA-21

FRONT AXLE Drive shaft (Cont’d) Wheel side (90AC, 98AC and B86 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape so as not to damage boot during installation.

Tape

SFA800

Wheel bearing lock nut

2. Set joint assembly onto drive shaft by lightly tapping it. Install joint assembly securely, ensuring marks which were made during disassembly are correctly aligned.

SFA942A

3. Pack drive shaft with specified amount of grease. Specified amount of grease: 90AC type 80 - 110 m (2.8 - 3.9 Imp fl oz) 98AC type 110 - 130 m (3.9 - 4.6 Imp fl oz) B86 type 95 - 115 m (3.3 - 4.0 Imp fl oz)

SFA885

4. Make sure that boot is correctly installed on the drive shaft groove. Set boot so that it does not swell and deform when its length is “L1”. Length “L1”: 90AC type 89 - 91 mm (3.50 - 3.58 in) 98AC type 96 - 98 mm (3.78 - 3.86 in) L1 SFA886

5. Lock new larger and smaller boot bands securely with a suitable tool.

Boot band

SFA395

FA-22

FRONT AXLE Drive shaft (Cont’d)

Suitable tool

.

SFA472 SFA472

Transaxle side (GI69 type and GI82 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.

Tape

SFA800

2. Install spider assembly securely, making sure the marks which were made during disassembly are properly aligned. 3. Install new snap ring.

Snap ring SFA023A

4. Pack drive shaft with specified amount of grease. Specified amount of grease: GI69 type 165 - 175 m (5.8 - 6.2 Imp fl. oz) GI82 type 160 - 170 m (5.6 - 6.0 Imp fl. oz) 5. Install slide joint housing. 6. Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform.

Shaft groove SFA065A

7. Lock new larger and smaller boot bands securely with a suitable tool.

Boot band

SFA395

FA-23

FRONT AXLE Drive shaft (Cont’d) Transaxle side (D83/T83 type) 1. Install boot and new small boot band on drive shaft. Cover drive shaft serration with tape to prevent damage boot during installation.

Tape

SFA800

2. Install ball cage, inner race and balls as a unit, making sure the matching marks which were made during disassembly are properly aligned. 3. Install new snap ring “C”.

SFA514A

4. Pack drive shaft with specified amount of grease. Specified amount of grease: 115 - 135 m (4.0 - 4.8 Imp fl oz) 5. Install slide joint housing, then install new snap ring “A”. 6. Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform.

NFA050

7. Lock new larger and smaller boot bands securely with a suitable tool.

Boot band

SFA395

Support bearing ●

Press bearing into retainer.

Suitable tool

SFA618

FA-24

FRONT AXLE Drive shaft (Cont’d) ●

Press drive shaft into bearing.

● ●

Install snap ring. Install new dust shield.

Suitable tool

SFA694

SFA695

Transaxle side

SFA621

FA-25

FRONT SUSPENSION MODELS BEFORE VIN - P11U0559000 SEC. 391⋅400⋅401 When installing stabilizer bar and transverse link, final tightening requires to be carried out under unladen condition* with tires on the ground. 42 - 54 * Fuel, radiator coolant and engine oil full. (4.3 - 5.5, Spare tire, jack, hand tools and mats in 31 - 40) designated positions.

18 - 24 (1.8 - 2.4, 13 - 17) Upper bushing A Gasket Upper mounting Upper rubber seat Upper bushing B

Dust cover

Bound bumper rubber

Coil spring

Shock absorber

16 - 22 (1.6 - 2.2, 12 - 16) Washer 88 - 123 (9.0 - 12.5, 65 - 90)

Bushing Third link Upper link 112 - 126 (11.4 - 12.8, 82 - 93)

88 - 123 (9.0 - 12.5, 65 - 90) Upper link bracket

98 - 118 (10 - 12, 72 - 87)

112 - 126 (11.4 - 12.8, 82 - 93) 88 - 123 (9.0 - 12.5, 65 - 90)

Wheel hub end steering knuckle assembly

Cotter pin

71 - 86 (7.2 - 8.8, 52 - 63) 118 - 147 (12.0 - 15.0, 87.0 - 108.4)

Cotter pin Adjusting cap

Drive shaft

.

255 - 333 (26 - 34, 188 - 246)

Gusset pin Insulator 118 - 147 (12 - 15, 87 - 108)

Transverse link

118 - 147 (12 - 15, 87 - 108)

Connecting rod

Stabilizer bar

: N·m (kg-m, ft-lb)

42 - 49 (4.3 - 5.0, 31 - 36)

FA-26

42 - 49 (4.3 - 5.0, 31 - 36) NFA057

FRONT SUSPENSION MODELS AFTER VIN - P11U0559000

YFA002

FA-27

FRONT SUSPENSION Coil Spring and Shock Absorber REMOVAL AND INSTALLATION ● ●

Strut upper mounting

Remove shock absorber fixing bolt and nut (to hoodledge). Do not remove piston rod lock nut.

NFA034

DISASSEMBLY

Suitable bar

1. Set shock absorber on vise, then loosen piston rod lock nut. WARNING: ● Do not remove piston rod lock nut.

ST35652000 SFA020A

2. Compress spring with Tool so that shock absorber mounting insulator can be turned by hand. WARNING: Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The spring compressors must be tightened alternately so as not to tilt the spring.

HT71780000

SFA918A

3. Remove piston rod lock nut.

SFA919A

FA-28

FRONT SUSPENSION Coil Spring and Shock Absorber (Cont’d) INSPECTION Shock absorber assembly ● ● ●

Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occurring on welded or gland packing portions. Check piston rod for cracks, deformation or other damage. Replace if necessary.

Mounting insulator and rubber parts ● ●

Check cemented rubber-to-metal portion for separation or cracks. Check rubber parts for deterioration. Replace if necessary.

Coil spring ●

Check for cracks, deformation or other damage. Replace if necessary.

ASSEMBLY ●

When shock absorber is installed, it must be positioned so that arrow point A faces rearward on LH side, and forward on RH side.

●

Install upper spring seat with its cutout facing the inside of the vehicle.

SFA920A

Inside

Cutout SFA921A

Third Link and Upper Link REMOVAL CAUTION: Kingpin bearing usually does not require maintenance. If any of the following symptoms are noted, replace kingpin bearing assembly. ● Growling noise is emitted from kingpin bearing during operation. ● Kingpin bearing drags or turns roughly when steering knuckle is turned by hand.

FA-29

FRONT SUSPENSION Third Link and Upper Link (Cont’d) 1. 2. 3. 4.

Remove cap and kingpin nut. Remove shock absorber fixing nut and upper link fixing bolts. Remove stabilizer connecting rod. Remove third link and upper link.

SFA922A

INSTALLATION Third link ●

Pack kingpin housing and cap with multi-purpose grease. Grease capacity: Kingpin housing 4 g (0.14 oz) Cap 10 g (0.35 oz)

●

Install third link and cap.

Grease

SFA727A

SFA923A

Upper link ● Upper link has “L” or “R” stamped on it as shown. Upper link bushings cannot be disassembled. ● When installing upper link, make sure that parts are in their correct positions. ● Bushings have in-built play of between 0.5 to 1.0 mm (0.020 to 0.039 in).

R = Upper link (right) L = Upper link (left)

Stamping SFA924A

DISASSEMBLY ●

Remove upper bearing (inner race and ball).

Upper bearing SFA721A

FA-30

FRONT SUSPENSION Third Link and Upper Link (Cont’d) ●

Remove kingpin grease seal. Remove lower bearing (inner race and ball).

● ●

Remove upper and lower outer race. Be careful not to damage kingpin housing.

●

Lower bearing

Kingpin grease seal

SFA722A

Outer race Kingpin housing Outer race SFA723A

ASSEMBLY

Press

Press

Kingpin housing

Install lower bearing.

●

Install upper bearing.

●

Install lower oil seal. Apply multi-purpose grease to oil seal lip.

SFA724A

2.5 ± 0.2 mm (0.098 ± 0.008 in)

Kingpin housing

●

SFA725A

Press

● Grease

Kingpin grease seal

SFA726A

FA-31

FRONT SUSPENSION Transverse Link and Lower Ball Joint REMOVAL AND INSTALLATION ● ● ●

Remove tension rod, ball joint and transverse link assembly. During installation, final tightening must be done at curb weight with tires on ground. After installation, check wheel alignment. Refer to “Front Wheel Alignment”, “ON-VEHICLE SERVICE”, FA-6.

NFA036

INSPECTION Transverse link ● ●

Check transverse link for damage, cracks or deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary.

Lower ball joint A

●

B

C

SFA858A

●

Check ball joint for excessive play. Replace transverse link assembly if any of the following exists: ● Ball stud is worn. ● Joint is hard to swing. ● Play in axial direction is excessive. Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in. Swinging force “A”: (measuring point: cotter pin hole of ball stud) 7.8 - 57.9 N (0.8 - 5.9 kg, 1.8 - 13.0 lb) Turning torque “B”: 0.5 - 3.4 (5 - 35 kg-cm, 4.3 - 30.4 in-lb) Vertical end play “C”: 0 mm (0 in) Check dust cover for damage. Replace it and cover clamp if necessary.

Stabilizer Bar REMOVAL AND INSTALLATION CAUTION: — For models with xenon headlamps only ● When removing or installing stabilizer bar, take care not to damage headlamp leveling sensor. ● After installation of the stabilizer bar, the headlamp sensor has to be recalibrated. Refer to EL-section. ● Remove stabilizer bar. .

SFA925A

FA-32

FRONT SUSPENSION Stabilizer Bar (Cont’d) ●

When installing stabilizer, make sure that paint mark and clamp face in their correct directions.

●

When removing and installing stabilizer bar, hold part A as shown.

●

Install stabilizer bar with ball joint socket correctly located.

Stabilizer

Rear

Paint mark SRA198A

.

SFA926A

View from B

O.K.

N.G.

SFA002A

INSPECTION ● ● ●

Check stabilizer bar for deformation or cracks. Replace if necessary. Check rubber bushings for deterioration or cracks. Replace if necessary. Check ball joint can rotate in all directions. If movement is not smooth and free, replace stabilizer bar link.

ARA027

FA-33

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Suspension type

Independent multi-link strut with coil spring

Strut type

Double-acting hydraulic

Stabilizer bar

Standard equipment

DRIVE SHAFT QG16DE/ QG18DE

Applied model

CD20T

SR20DE M/T

CVT

Joint type Transaxle side

GI82

D83/T83

Wheel side

98AC

B86

Transaxle side “D1”

26 (1.02)

25 (0.98)

Wheel side “D2”

28 (1.10)

27 (1.06)

Diameter (Serration)

mm (in)

Grease Quality Capacity

Nissan Genuine Grease or equivalent m (Imp fl oz)

Transaxle side

175 - 185 (6.2 - 6.5)

115 - 135 (4.0 - 4.8)

Wheel side

110 - 130 (3.9 - 4.6)

95 - 115 (3.3 - 4.0)

96 - 98 (3.78 - 3.86)

96 - 98 (3.78 - 3.86)

Boot length

mm (in)

Wheel side “L” Wheel side

Transaxle side

SFA928A

FA-34

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment WHEEL ALIGNMENT (Unladen*1) 195/60 R15 195/60 VR15 185/65 HR15

Applied model Camber

205/50 R16

Minimum

−0°45′

Degree minute Nominal

Caster

0°

Maximum

0°45′

Minimum

1°10′

Degree minute Nominal

Kingpin inclination

1°55′

Maximum

2°40′

Minimum

13°45′

Degree minute Nominal

14°30′

Maximum Total toe-in

15°15′

Minimum Distance (A - B)

0 (0)

Nominal

1 (0.04)

mm (in) Maximum Angle (left plus right)

2 (0.08)

Minimum

0°

Degree minute Nominal

0°6′

Maximum Wheel turning angle Full turn *2

0°12′

Minimum

32

31

Nominal

35

34

Inside

Degree minute Maximum

36

35

Outside

Degree minute Nominal

30

29

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

WHEEL BEARING

LOWER BALL JOINT

Wheel bearing axial end play limit mm (in)

0.05 (0.0020) or less

Wheel bearing lock nut tightening torque N·m (kg-m, ft-lb)

235 - 314 (24 - 32, 174 - 231)

Ball stud swinging force at cotter pin hole N (kg, lb)

7.8 - 57.9 (0.8 - 5.9, 6 - 42)

Ball stud rotating torque N·m (kg-cm, in-lb)

0.5 - 3.4 (5 - 34, 5 - 30)

Ball stud axial end play limit mm (in)

0 (0)

WHEEL RUNOUT Wheel type

Aluminium

Steel

Radial runout limit

mm (in)

0.3 (0.012)

0.5 (0.020)

Lateral runout limit

mm (in)

0.3 (0.012)

0.8 (0.031)

FA-35

SERVICE DATA AND SPECIFICATIONS (SDS) NOTE

FA-36

REAR AXLE & REAR SUSPENSION SECTION

RA

CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Special Service Tools ................................................ 2 Commercial Service Tools ......................................... 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 3 NVH Troubleshooting Chart....................................... 3 REAR SUSPENSION SYSTEM..................................... 4 ON-VEHICLE SERVICE ................................................ 5 Rear Axle and Rear Suspension Parts ..................... 5 Rear Wheel Bearing .................................................. 5

Rear Wheel Alignment............................................... 6 REAR AXLE................................................................... 7 Wheel Hub ................................................................. 7 REAR SUSPENSION..................................................... 9 Removal and Installation ......................................... 10 Coil Spring and Shock Absorber ..............................11 Torsion Beam, Lateral Link and Control Rod .......... 12 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 14 General Specifications............................................. 14 Inspection and Adjustment ...................................... 14

RA

PRECAUTIONS AND PREPARATION Precautions ●

● GG94310000

● SBR820B

● ●

When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Use flare nut wrench when removing or installing brake tubes. After installing removed suspension parts, check wheel alignment. Do not jack up at the trailing arm and lateral link. Always torque brake lines when installing.

Special Service Tools Tool number Tool name

Description

GG94310000 Flare nut torque wrench

Removing and installing brake piping

a: 10 mm (0.39 in)

NT406

HT71780000 Spring compressor

Removing and installing coil spring

NT144

KV40106400 Piston rod lock nut wrench

a: b: c: d: e: f :

NT369

ST35652000 Shock absorber attachment

5 mm (0.20) 16.2 mm (0.64 in) DIA 52 mm (2.05 in) 14 mm (0.55 in) 25.4 mm (1.00 in) DIA 55 mm (2.17 in)

Fixing strut assembly

NT145

Commercial Service Tools Tool name

Description

Equivalent to GG94310000 1 Flare nut crows foot p 2 p Torque wrench

Removing and installing brake piping

a: 10 mm (0.39 in)

NT360

RA-2

X

X

X

X

—

X

Suspension looseness

RA-9

Incorrect wheel alignment

RA-14

Wheel bearing damage

RA-5

X

X

Spring fatigue

X

—

X

X

X

Parts interference

X

NVH in FA section

ROAD WHEEL

NVH in FA section

BRAKES

NVH in BR section

X

X

TIRES

X

X X

X

X

NVH in FA section

X

X

X

X

FRONT AXLE AND FRONT SUSPENSION

X

X

X

X

X

X

NVH in FA section

X

X

X

X

X

X

X

X

X X

X

X

DRIVE SHAFT

STEERING

NVH in ST section

NVH Troubleshooting Chart

RA-11

Bushing or mounting deterioration

X

RA-11

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Shock absorber deformation, damage or deflection

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Noise

Shake

Vibration

Shimmy

Judder

Poor quality ride or handling

RA-9

Use the chart below to help you to find the cause of the symptom. If necessary, repair or replace these parts.

Reference page

REAR AXLE AND REAR SUSPENSION

Possible cause and SUSPECTED PARTS

Symptom

X: Applicable

RA-3

Improper installation, looseness

REAR SUSPENSION SYSTEM SEC. 431 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

p1

98 - 118 (10 - 12, 73 - 87)

42 - 57 (4.3 - 5.8, 31 - 42)

p2 p4 p5 p3

Front

98 - 118 (10 - 12, 73 - 87)

: Do not re-use : N·m (kg-m, ft-lb) NRA004 1 p 2 p

Coil spring Shock absorber

3 p 4 p

Torsion beam Lateral link

RA-4

5 p

Control rod

ON-VEHICLE SERVICE Rear Axle and Rear Suspension Parts Check axle and suspension parts for excessive play, wear or damage. ● Shake each rear wheel to check for excessive play.

SMA525A

●

Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to REAR SUSPENSION (RA-9).

●

Check shock absorber for oil leakage or other damage.

NRA005

SMA113

Rear Wheel Bearing ●

● ● ●

SRA690A

Check axial end play. Axial end play: 0.00 mm (0.0000 in) Check that wheel hub bearings operate smoothly. Check tightening torque of wheel bearing lock nut. : 187 - 255 N·m (19 - 26 kg-m, 138 - 188 ft-lb) Replace wheel bearing assembly if there is axial end play or wheel bearing does not turn smoothly. Refer to REAR AXLE — Wheel Hub (RA-7).

RA-5

ON-VEHICLE SERVICE Rear Wheel Alignment PRELIMINARY INSPECTION

Lateral runout

Radial runout

SFA975B

Make following checks. Adjust, repair or replace if necessary. ● Check tires for wear and for improper inflation. ● Check rear wheel bearings for excessive play. ● Check wheels for deformation, cracks and other damage. If deformed, remove tire and check wheel runout. Wheel runout: Refer to SDS in FA section. ● Check that rear shock absorber functions correctly. ● Check rear axle and rear suspension parts for excessive play. ● Check vehicle posture (Unladen*). *: Fuel, radiator and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

CAMBER Camber is preset at factory and cannot be adjusted. Camber: Refer to SDS (RA-14). ● If the camber is not within specification, inspect and replace any damaged or worn rear suspension parts.

SFA948A

TOE-IN Front

Hub center height

Base line Measuring point

SFA614B

SFA234AC

Toe-in is preset at factory and cannot be adjusted. Measure toe-in using following procedure. If out of specification, inspect and replace any damaged or worn rear suspension parts. WARNING: ● Always perform following procedure on a flat surface. ● Make sure that no person is in front of the vehicle before pushing it. 1. Bounce rear of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead about 5 m (16 ft). 3. Put a mark on base line of the tread (rear side) of both tires at the same height of hub center. This mark is a measuring point. 4. Measure distance “A” (rear side). 5. Push the vehicle slowly ahead to rotate the wheels 180 degrees (1/2 turn). If the wheels have rotated more than 180 degrees (1/2 turn), try the above procedure again from the beginning. Never push vehicle backward. 6. Measure distance “B” (front side). Total toe-in: Refer to SDS, RA-14.

RA-6

REAR AXLE Wheel Hub SEC. 430

187 - 255 (19 - 26, 138 - 188)

25 - 33 (2.6 - 3.3, 19 - 24) 22 - 29 (2.3 - 2.9, 17 - 21)

Front

: Do not re-use : N·m (kg-m, ft-lb) 1 p 2 p 3 p

Spindle Baffle plate Wheel hub bearing

NRA015 4 p 5 p

Wheel bearing lock nut Cotter pin

6 p 7 p

Hub cap ABS sensor

REMOVAL CAUTION: ● Before removing the rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly. Then move it away from the hub assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. ● Wheel hub bearing does not require maintenance. If any of the following symptoms are noted, replace wheel hub bearing assembly. ● Growling noise is emitted from wheel hub bearing during operation. ● Wheel hub bearing drags or turns roughly. This occurs when turning hub by hand after bearing lock nut is tightened to specified torque.

RA-7

REAR AXLE Wheel Hub (Cont’d) 1. Remove brake caliper assembly. 2. Remove brake rotor. 3. Remove wheel bearing lock nut. 4. Remove wheel hub bearing from spindle. Brake hose does not need to be disconnected from brake caliper. Suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SRA711A

INSTALLATION ● ●

●

Install wheel hub bearing. Tighten wheel bearing lock nut. Before tightening, apply oil to threaded portion of rear spindle and both sides of plain washer. : 187 - 255 N·m (19 - 26 kg-m, 138 - 188 ft-lb) Check that wheel bearings operate smoothly.

SRA712A

●

Check wheel hub bearing axial end play. Axial end play: 0.00 mm (0.0000 in)

SRA690A

RA-8

REAR SUSPENSION SEC. 431 When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. 36 - 47 (3.7 - 4.7, 27 - 34)

p6

p1 p2

p3 42 - 57 (4.3 - 5.8, 31 - 42)

p7

p 4

25 - 33 (2.6 - 3.3, 19 - 24)

p5

11 p

p8

98 - 118 (10 - 12, 73 - 87)

p9

98 - 118 (10 - 12, 73 - 87)

59 - 78 (6.1 - 7.9, 44 - 57) 98 - 118 (10 - 12, 73 - 87) 10 p

98 - 118 (10 - 12, 73 - 87) 98 - 118 (10 - 12, 73 - 87) : N·m (kg-m, ft-lb)

Front

: Do not re-use

1 p 2 p 3 p 4 p

Washer Bushing Shock absorber mounting bracket Bound bumper cover

5 p 6 p 7 p 8 p

Bound bumper Coil spring Shock absorber Torsion beam

RA-9

9 p 10 p 11 p

Lateral link Control rod ABS sensor

NRA018

REAR SUSPENSION Removal and Installation

SRA695A

CAUTION: ● Before removing the rear suspension assembly, disconnect the ABS wheel sensor and headlamp leveling sensor from the assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. ● Remove suspension assembly. 1. Disconnect parking brake cable from caliper and remove brake caliper and rotor. Suspend caliper assembly with wire so as not to stretch brake hose.

Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. 2. Using a transmission jack, raise torsion beam a little, and remove nuts and bolts from the trailing arm, shock absorber assembly (lower side) and lateral link. 3. Lower transmission jack, and remove suspension. 4. Remove shock absorber assembly.

NRA016

● Install suspension assembly. CAUTION: Refill with new brake fluid “DOT 4”. Never reuse drained brake fluid. ● After installation of the suspension assembly the headlamp leveling sensor has to be recalibrated. Refer to EL section (models equipped with xenon headlamps only). 1. Attach torsion beam, at trailing arm and lateral link, to vehicle. Do not tighten bolts at this time. SRA697A

2. Using a transmission jack, place lateral link and control rod horizontally against torsion beam. Tighten lateral link on vehicle. 3. Attach shock absorber assembly to vehicle. Then tighten the lower side of shock absorber assembly. 4. Lower torsion beam to fully extended position. Remove transmission jack and tighten torsion beam, at trailing arm, to specified torque. Refer to RA-9. 5. Install ABS-wheel sensor. SRA698A

RA-10

REAR SUSPENSION Coil Spring and Shock Absorber REMOVAL Remove shock absorber upper and lower fixing nuts. Do not remove piston rod lock nut on vehicle.

DISASSEMBLY 1. Set shock absorber in vise with attachment, then loosen piston rod lock nut. WARNING: Do not remove piston rod lock nut at this time. 2. Compress spring with Tool so that the shock absorber upper spring seat can be turned by hand.

Suitable bar

NRA008

3. Remove piston rod lock nut.

NRA009

INSPECTION Shock absorber assembly ● ● ●

Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage on welded or gland packing portions. Check piston rod for cracks, deformation or other damage. Replace if necessary.

Upper rubber seat and bushing Check rubber parts for deterioration or cracks. Replace if necessary.

Coil spring Check for cracks, deformation or other damage. Replace if necessary.

RA-11

REAR SUSPENSION Coil Spring and Shock Absorber (Cont’d) Shock absorber lower bushing center

LH

Front 12.8°

12.8°

Spring lower end position

Spring lower end position

ASSEMBLY ●

Locate upper spring seat as shown.

●

When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.) When installing coil spring on shock absorber, it must be positioned as shown in figure at left.

RH NRA010

●

SFA436B

Torsion Beam, Lateral Link and Control Rod DISASSEMBLY ● ●

Remove torsion beam assembly. Refer to Removal and Installation in REAR SUSPENSION (RA-10). Remove lateral link and control rod from torsion beam.

INSPECTION ● SRA703A

●

Check for cracks, distortion or other damage. Replace if necessary. Standard length: A 207 - 208 mm (8.15 - 8.19 in) B 394 - 395 mm (15.51 - 15.55 in) C 601 - 603 mm (23.66 - 23.74 in) D 106 - 108 mm (4.17 - 4.25 in) Check all rubber parts for wear, cracks or deformation. Replace if necessary.

ASSEMBLY 1. Temporarily assemble lateral link and control rod. ● When installing the control rod, connect the bush with the smaller inner diameter to the lateral link.

SRA700A

RA-12

REAR SUSPENSION Torsion Beam, Lateral Link and Control Rod (Cont’d) 2. Temporarily install lateral link and control rod on torsion beam. ● When installing, place lateral link with the arrow topside.

SRA701A

3. Place lateral link and control rod horizontally against torsion beam, and tighten to the specified torque. 4. Install torsion beam assembly. Refer to Removal and Installation in REAR SUSPENSION (RA-10).

SRA702A

RA-13

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Suspension type

Multi-link beam suspension

Shock absorber type

Double-acting hydraulic

Stabilizer

Standard equipment

Inspection and Adjustment WHEEL ALIGNMENT (Unladen*) Camber

Minimum

−2°9′ (−2.15°)

Nominal

−1°24′ (−1.4°)

Degree minute (Decimal degree) Maximum Total toe-in

WHEEL BEARING

−0°39′ (−0.65°)

Minimum

−1.8 (−0.07)

Nominal

2.2 (0.09)

Distance (A−B) mm (in) Maximum Angle (left plus right) Minimum Nominal Degree minute (Decimal degree) Maximum

Wheel bearing axial end play mm (in)

0.0 (0.00)

Wheel bearing lock nut tightening torque N·m (kg-m, ft-lb)

187 - 255 (19 - 26, 138 - 188)

6.2 (0.24) −0°11′24″ (−0.19°) 0°12′36″ (0.21°) 0°36′36″ (0.61°)

*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

RA-14

BRAKE SYSTEM SECTION

BR

CONTENTS PRECAUTIONS ............................................................. 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for Brake System................................... 3 Precautions When Working On ABS......................... 4 Wiring Diagrams and Trouble Diagnosis................... 4 PRECAUTIONS AND PREPARATION.......................... 5 Commercial Service Tools ......................................... 5 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING.................................................. 6 NVH Troubleshooting Chart....................................... 6 CHECK AND ADJUSTMENT ........................................ 7 Checking Brake Fluid Level....................................... 7 Checking Brake Line ................................................. 7 Changing Brake Fluid ................................................ 7 Brake Burnishing Procedure...................................... 7 Bleeding Brake System ............................................. 8 BRAKE HYDRAULIC LINE ........................................... 9 Removal................................................................... 10 Inspection................................................................. 10 Installation................................................................ 10 CONTROL VALVE ........................................................11 Dual Proportioning Valve ..........................................11 BRAKE PEDAL AND BRACKET................................ 13 Removal and Installation ......................................... 13 Inspection................................................................. 13 Adjustment ............................................................... 13 MASTER CYLINDER................................................... 15 Removal................................................................... 15 Disassembly............................................................. 15 Inspection................................................................. 16 Assembly ................................................................. 16 Installation................................................................ 17

BRAKE BOOSTER...................................................... 18 On-vehicle Service................................................... 18 Removal................................................................... 18 Inspection................................................................. 19 Installation................................................................ 19 VACUUM HOSE........................................................... 20 Removal and Installation ......................................... 21 Inspection................................................................. 21 FRONT DISC BRAKE ................................................. 23 Pad Replacement .................................................... 23 Removal................................................................... 24 Disassembly............................................................. 25 Inspection - Caliper.................................................. 25

SR20DE - M/T FRONT DISC BRAKE ................................................. 26 Pad Replacement .................................................... 26 Installation................................................................ 28 Removal................................................................... 29 Disassembly............................................................. 29 Inspection - Caliper.................................................. 29

FRONT DISC BRAKE ................................................. 31 Inspection - Rotor .................................................... 31 Assembly ................................................................. 31 Installation................................................................ 32 REAR DISC BRAKE TYPE 1...................................... 33 Component .............................................................. 33 Pad Replacement .................................................... 33 Removal................................................................... 35 Disassembly............................................................. 35

BR

Inspection................................................................. 36 Assembly ................................................................. 37 Installation................................................................ 39 REAR DISC BRAKE TYPE 2...................................... 40 Component .............................................................. 40 Pad Replacement .................................................... 40 Removal................................................................... 42 Disassembly............................................................. 42 Inspection................................................................. 42 Installation................................................................ 43 REAR DRUM BRAKE ................................................. 44 Components............................................................. 44 Removal................................................................... 44 Inspection - Wheel Cylinder .................................... 45 Wheel Cylinder Overhaul......................................... 46 Inspection - Drum .................................................... 46 Inspection - Lining ................................................... 46 Installation................................................................ 46 PARKING BRAKE CONTROL .................................... 48 Removal and Installation ......................................... 48 Inspection................................................................. 49 Adjustment ............................................................... 49 ANTI-LOCK BRAKE SYSTEM.................................... 50 Purpose.................................................................... 50 Operation ................................................................. 50 ABS Hydraulic Circuit .............................................. 50 System Components ............................................... 51 System Description.................................................. 51 Removal and Installation ......................................... 53 TROUBLE DIAGNOSES ............................................. 57 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 57 Preliminary Check.................................................... 59 Component Parts and Harness Connector Location ................................................................... 60 Circuit Diagram for Quick Pinpoint Check............... 61

Wiring Diagram - ABS - ........................................... 62 Self-diagnosis (Only models with data link connector terminal No. 8) ........................................ 67 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 69 CONSULT-II ............................................................. 69 CONSULT-II Inspection Procedure.......................... 70 Ground Circuit Check .............................................. 75 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................. 76 Malfunction Code/Symptom Chart........................... 76 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................... 77 Diagnostic Procedure 1 (Wheel sensor or rotor) .... 77 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay) ............................... 79 Diagnostic Procedure 3 (Motor Relay or motor) ..... 81 Diagnostic Procedure 4 (Low voltage) .................... 83 Diagnostic Procedure 5 (Control unit) ..................... 84 TROUBLE DIAGNOSES FOR SYMPTOMS............... 85 Diagnostic Procedure 6 (ABS works frequently)..... 85 Diagnostic Procedure 7 (Unexpected pedal action) ...................................................................... 86 Diagnostic Procedure 8 (Long stopping distance) .. 86 Diagnostic Procedure 9 (ABS does not work.) ....... 87 Diagnostic Procedure 10 (Pedal vibration and noise) ....................................................................... 87 Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON) .......................................................................... 88 Diagnostic Procedure 12 (Warning lamp stays on when ignition switch is turned ON).......................... 90 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 91 General Specifications............................................. 91 Inspection and Adjustment ...................................... 92

When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

BR-2

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to the destination and optional equipment.): ● For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just before the harness connectors or for the complete harness are related to the SRS.

Precautions for Brake System Recommended fluid is brake fluid “DOT 4”. Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. ● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. ● Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. ● Use flare nut wrench when removing and installing brake tube. ● Always torque brake lines when installing. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “Check and Adjustment”, BR-7. WARNING: ● Clean brake pads with a waste cloth, then wipe with a dust collector. ● ●

Commercial service tool SBR686C

BR-3

PRECAUTIONS Precautions When Working On ABS ● ● ●

● ●

● ●

Use recommended tyres in combination with ABS. Install tyres or studded tyres, etc. with the same size. If different sizes of tyres, or tyres other than the ones recommended for use with the ABS, are fitted, stopping distance will increase and control and stability could deteriorate. When changing brake pads, use Nissan genuine parts. When fitting radios etc, do not position the radio unit, antenna, or antenna cables within an area of about 100 mm (3.94 in) of the control unit. When doing any work that requires electro-welding, first remove the control unit. Make sure when taking a power supply for the audio, lamps etc., not to take this from any ABS-related harness. (Refer to the electrical wiring diagrams for ABSrelated harnesses)

Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: ● GI-11, “HOW TO READ WIRING DIAGRAMS” ● EL-10, “POWER SUPPLY ROUTING” When you perform trouble diagnosis, refer to the following: ● GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS” ● GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT”

BR-4

PRECAUTIONS AND PREPARATION Commercial Service Tools Tool name 1 p 2 p

Description

Flare nut crows foot Torque wrench

Removing and installing each brake piping

a: 10 mm (0.39 in)

NT360

Brake fluid pressure gauge

Measuring brake fluid pressure

NT151

BR-5

x x

Shims damaged

BR-23, 33

x x

Rotor imbalance

—

x

Rotor damaged

BR-31, 37, 43

x

Rotor runout

BR-31, 37, 43

x

Rotor deformation

—

x

Rotor deflection

—

x

Rotor rust

—

x

Rotor thickness variation

BR-31, 37

PROPELLER SHAFT

NHV in PD section

DIFFERENTIAL

NHV in PD section

x x x

AXLE AND SUSPENSION

NHV in FA, RA section

x x x

TIRES

NHV in FA section

x x x

ROAD WHEEL

NHV in FA section

AXLE SHAFT

NHV in FA section

STEERING

NHV in ST section

NVH Troubleshooting Chart

x

BR-23 26, 33

x x

Pads - uneven wear

x x x

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING

Noise Shake Shimmy, Judder BR-23, 26, 33

Use the chart to help you find the cause of the symptom. If necessary, repair or replace these parts.

Reference page

BRAKE

Possible cause and SUSPECTED PARTS

Symptom

X : Applicable

BR-6

Pads - damaged

x x x

CHECK AND ADJUSTMENT Checking Brake Fluid Level ● ●

MAX.

●

MIN.

Check fluid level in reservoir tank. It should be between Max. and Min. lines on reservoir tank. If fluid level is extremely low, check brake system for leaks. If brake warning lamp comes on and fluid level is above “MIN” mark, check brake fluid level switch and parking brake switch.

NBR141

Checking Brake Line CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. Check for oil leakage by fully depressing brake pedal while engine is running. ABR159

Changing Brake Fluid

SBR419C

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Always keep fluid level higher than minimum line on reservoir tank. ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. 1. Clean inside of reservoir tank, and refill with new brake fluid. 2. Connect a vinyl tube to each air bleeder valve. 3. Drain brake fluid from each air bleeder valve by depressing brake pedal while keeping reservoir level higher than minimum line by adding new brake fluid. 4. Repeat until new brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to “Bleeding Brake System”, BR-8.

Brake Burnishing Procedure Burnish the brake contact surfaces according to the following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. 1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).

BR-7

CHECK AND ADJUSTMENT Brake Burnishing Procedure (Cont’d) 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/ foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Bleeding Brake System

SBR995

SBR419C

CAUTION: ● Carefully monitor brake fluid level at master cylinder during bleeding operation. ● If master cylinder is suspected to have air inside, bleed air from master cylinder first. Refer to “Installation”, “MASTER CYLINDER”, BR-17. ● Fill reservoir with new brake fluid “DOT 4”. Make sure it is full at all times while bleeding air out of system. ● Place a container under master cylinder to avoid spillage of brake fluid. ● For models with ABS, turn ignition switch to the OFF position and disconnect ABS fuse or battery cable. ● Bleed air in the following order:

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

RHD models Left rear brake,Right front brake,Right rear brake,Left front brake LHD models Right rear brake,Left front brake,Left rear brake,Right front brake. Connect a transparent vinyl tube to air bleeder valve. Fully depress brake pedal several times. With brake pedal depressed, open air bleeder valve to release air. Close air bleeder valve. Release brake pedal slowly. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve. Tighten air bleeder valve. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)

BR-8

BRAKE HYDRAULIC LINE

NBR434

BR-9

BRAKE HYDRAULIC LINE Removal

SBR419C

CAUTION: ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● All hoses and tubes must be free from excessive bending, twisting and pulling. ● For rear disc caliper, care should be taken as not to let air enter the body. 1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Remove flare nut securing brake tube to hose, then withdraw lock spring. 4. Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line.

Inspection Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.

Installation

Commercial service tool SBR686C

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Tighten all flare nuts and connecting bolts. Flare nut: : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Connecting bolt: : 17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb) 2. Refill until new brake fluid comes out of each air bleeder valve. 3. Bleed air. Refer to “Bleeding Brake System”, BR-8.

BR-10

CONTROL VALVE Dual Proportioning Valve Brake fluid pressure gauge

SBR822BA

Brake fluid pressure gauge

INSPECTION CAUTION: ● Carefully monitor brake fluid level at master cylinder. ● Use new brake fluid “DOT 4”. ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on paint areas, wash it away with water immediately. ● Depress pedal slowly when raising front brake pressure. ● Check rear brake pressure at least 2 seconds after front brake pressure reaches specified value. 1. Connect brake fluid pressure gauge to air bleeders of front and rear brakes on either LH or RH side. 2. Bleed air from the tool. 3. Check fluid pressure by depressing brake pedal. Unit: kPa (bar, kg/cm2, psi) Applied pressure (Front brake)

5.39 (53.9, 55, 781.6)

Output pressure (Rear brake)

3.132 - 3.532 (31.32 - 35.32, 31.94 - 36.02, 454.3 - 512.3)

SBR823BA

If output pressure is out of specifications, replace dual proportioning valve. 4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake System”, BR-8.

REMOVAL

NBR145

CAUTION: ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● All tubes must be free from excessive bending, twisting and pulling. 1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Loosen flare nut. 4. Remove proportioning valve mounting bolt, then remove flare nut.

BR-11

CONTROL VALVE Dual Proportioning Valve (Cont’d) INSTALLATION CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Temporarily fit flare nut to proportioning valve. 2. Tighten proportioning valve mounting bolt, then tighten flare nut with wooden block placed between proportioning valve and dash panel. Flare nut: : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Mounting bolt: : 5.1 - 8.8 N·m (0.52 - 0.9 kg-m, 45 - 78 in-lb) 3. Refill until new brake fluid comes out of each air bleeder valve. 4. Bleed air. Refer to “Bleeding Brake System”, BR-8.

BR-12

BRAKE PEDAL AND BRACKET Removal and Installation

NBR435

Inspection Stopper

Check brake pedal for following items: ● Brake pedal bend ● Clevis pin deformation ● Crack of any welded portion ● Crack or deformation of clevis pin stopper.

SBR997

Adjustment

Clevis lock nut 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) Input rod Brake lamp switch and redundant brake switch

C1 or C2

Check brake pedal free height from dash reinforcement panel. H: Free height Refer to SDS, BR-92. D: Depressed height Refer to SDS, BR-92. C1, C2: Clearance between pedal stopper rubber and threaded end of brake lamp switch (or redundant brake switch). 0.75 - 2.0 mm (0.03 - 0.08 in) A: Pedal free play 1 - 3 mm (0.039 - 0.118 in)

A

Floor carpet Dash insulator

90°

D

Floor carpet H

Dash insulator

Floor panel Melt sheet SBR110B

BR-13

BRAKE PEDAL AND BRACKET Adjustment (Cont’d) Stays inside

Lock nut Input rod

Clevis

1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. 2. Check pedal free play. Make sure that brake lamps go off when pedal is released. 3. Check brake pedal’s depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.

SBR229E

BR-14

MASTER CYLINDER Removal

NBR436

1. 2. 3. 4.

Reservoir cap Oil filter Reservoir tank Seal

5. 6. 7.

Cylinder body Elastic pin Piston stopper pin

8. Secondary piston assembly 9. Primary piston assembly 10. Circlip

CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. 1. Disconnect fluid level connector. 2. Connect a vinyl tube to air bleeder valve. 3. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder. 4. Remove brake pipe flare nuts. 5. Remove master cylinder mounting nuts.

Disassembly 1. Drive out elastic pin from cylinder body. 2. Remove reservoir tank and seals.

SBR231E

BR-15

MASTER CYLINDER Disassembly (Cont’d) 3. Remove the circlip with suitable pliers while piston is pushed into cylinder.

NBR353

4. Remove piston stopper pin while piston is pushed into cylinder. 5. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.

Push

Piston stopper pin SBR232E

Inspection Check for the following items. Replace any part if damaged. Master cylinder: ● Pin holes or scratches on inner wall. Piston: ● Deformation of or scratches on piston cups.

Assembly

Secondary piston

1. Insert secondary piston assembly. Then insert primary piston assembly. ● Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body. Primary piston

SBR233E

2. Install piston stopper pin while piston is pushed into cylinder. Then secure the primary and secondary piston assemblies with new circlip. 3. Push reservoir tank seals and reservoir tank into cylinder body. 4. Install elastic pin.

Push

Piston stopper pin SBR232E

BR-16

MASTER CYLINDER Installation

SBR236E

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. : 14 - 17 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb) 3. Fill up reservoir tank with new brake fluid. 4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal. 5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder. 6. Fit brake lines to master cylinder. 7. Tighten flare nuts. : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) 8. Connect fluid level connector. 9. Bleed air from brake system. Refer to “Bleeding Brake System”, BR-8.

BR-17

BRAKE BOOSTER On-vehicle Service OPERATING CHECK 1. Depress brake pedal several times with engine off. After exhausting vacuum, make sure there is no change in pedal stroke. 2. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal.

SBR002A

AIRTIGHT CHECK OK

NG

Third

1. Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. Booster is airtight if pedal stroke is less each time. 2. Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds.

Second First SBR365AA

Removal CAUTION: ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● Be careful not to deform or bend brake pipes, during removal of booster.

NBR437

BR-18

BRAKE BOOSTER Inspection Output rod length

OUTPUT ROD LENGTH CHECK 1. Supply brake booster with vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69 inHg) using a hand vacuum pump. 2. Add preload of 19.6N (2.0 kg, 4.4lb) to output rod. 3. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in) SBR281A

Installation Approx. 125 - 127.5 (4.92 - 5.02)

Clevis locknut

mm (in)

Clevis NBR191

CAUTION: ● Be careful not to deform or bend brake pipes during installation of booster. ● Replace clevis pin if damaged. ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Take care not to damage brake booster mounting bolt thread when installing. Due to the acute angle of installation, the threads can be damaged on the metal surrounding the dash panel holes. 1. Before fitting booster, temporarily adjust clevis to dimension shown in the table. Adjustment mm (in) LHD

127.5 (5.02)

RHD

125 (4.92)

2. Fit booster, then secure mounting nuts (brake pedal bracket to booster) lightly. 3. Connect brake pedal and booster input rod with clevis pin. 4. Secure mounting nuts. Specification: : 11 - 17 N·m (1.2 - 1.7 kg-m, 9 - 12 ft-lb) 5. Install master cylinder. Refer to BR-14. 6. Bleed air. Refer to “Bleeding Brake System”, BR-8. 7. Adjust pedal height to specification. Refer to SDS (BR-92). Retighten clevis locknut. Specification: : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

BR-19

VACUUM HOSE LHD Petrol models

Tube

To intake manifold

Check valve

Vacuum hose

To Brake booster

RHD Petrol models

To brake booster

Check valve .

To Intake manifold

Vacuum hose

Diesel models Check valve Vacuum reservoir

NBR421

BR-20

VACUUM HOSE Removal and Installation

More than 24 mm (0.94 in)

Connect hose until it contacts protrusion on vacuum tube.

CAUTION: When installing vacuum hoses, pay attention to the following points. ● Do not apply any oil or lubricants to vacuum hose and check valve. ● Insert vacuum tube into vacuum hose as shown.

SBR225B

●

Intake manifold side

Install check valve, paying attention to its direction.

Brake booster side

SBR498A

CAUTION

Caution label ENG.

NBR385

Inspection HOSES AND CONNECTORS Check vacuum lines, connections and check valve for air tightness, improper attachment, chafing and deterioration.

CHECK VALVE Check vacuum with a vacuum pump. Booster side

Engine side

Connect to booster side

Vacuum should exist.

Connect to engine side

Vacuum should not exist.

SBR943A

BR-21

VACUUM HOSE Inspection (Cont’d)

Booster side Engine side Arrow indicates engine side

SBR844B

VACUUM PUMP Vacuum gauge

1. Install vacuum gauge. 2. Run engine at 1,000 rpm or more. 3. Check vacuum. Specified vacuum: 86.6 kPa (866 mbar, 650 mmHg, 25.59 inHg) or more

SBR209DA

BR-22

FRONT DISC BRAKE

NBR438

Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. ● If shims are rusted or show peeling of the rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.

BR-23

FRONT DISC BRAKE Pad Replacement (Cont’d) 1. Remove master cylinder reservoir cap. 2. Remove lower pin bolt.

NBR156

3. Open cylinder body upward. Then remove pad retainers, and inner and outer shims. Standard pad thickness: 11 mm (0.43 in) Pad wear limit: 2.0 mm (0.079 in) Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

Wire

SBR079B

Removal WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials.

CAUTION:

NBR159

Suspend caliper assembly with wire so as not to stretch brake hose. Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly.

BR-24

FRONT DISC BRAKE Disassembly WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with dust seal with compressed air. 2. Remove piston seal with suitable tool.

SBR772

Inspection — Caliper CYLINDER BODY Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil. ●

PISTON CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

BR-25

FRONT DISC BRAKE

SR20DE - M/T

NBR439

Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. ● If shims are rusted or show peeling of the rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.

BR-26

FRONT DISC BRAKE Pad Replacement (Cont’d) Torque member lug Cylinder body

Spring

SR20DE - M/T

REMOVAL 1. Remove the housing retaining spring. 2. Wipe away any dirt from the guide pins between the torque member and the cylinder body.

Locating holes .

Torque member lug

NBR292

Protective caps

3. Pull out the protective caps from the guide sleeves. 4. Use a 7 - mm ALLEN key to unscrew the guide pins from the torque member. 5. Partially remove the guide pins from the guide sleeve.

NBR300

6. Pull the cylinder body manually towards the outer side of the vehicle so that the piston is slightly pressed back. 7. Remove the cylinder body and hang it on a wire in the wheel arch in a suitable position. Make sure there is no strain on the brake hose piping. 8. Remove the brake pad on the piston side from the piston. 9. Remove the second brake pad from the torque member.

Wire

Spring

NBR290

BR-27

FRONT DISC BRAKE Pad Replacement (Cont’d)

SR20DE - M/T

CAUTION: Do not use any sharp tools or cleaning agents which contains mineral oil. Damage to the installation can occur. 10. Clean the cylinder body and guide grooves in the torque member. 11. Check the dust cover and guide sleeves for damage. 12. Measure the amount of wear on the brake pad Standard pad thickness: 11 mm (0.43 in) Pad wear limit: 2.0 mm (0.079 in) 14. Press the piston fully back with a suitable tool. CAUTION: Carefully monitor brake fluid level to avoid brake fluid from returning to the reservoir when pushing back the piston.

Installation

Wire Piston

Cylinder body Torque member

1. Install the brake pad with a three-pronged retaining spring into the piston. 2. Place the second brake pad into the guide groove of the torque member on the outer side of the brake disc. 3. Place the cylinder body with the installed brake pad over the brake disc and the second brake pad.

Guide groove

Second brake pad Three-pronged brake pad

NBR303

Protective caps Guide pins

4. Tighten the guide pins with a 7 - mm Allen key. 5. Press back the protective caps into the guides sleeve.

25 - 30 (2.5 - 3.1, 18 - 22)

.

N·m (kg-m, ft-lb)

NBR299

BR-28

FRONT DISC BRAKE Installation (Cont’d) Torque member lug Cylinder body

Spring

SR20DE - M/T

6. Check the cylinder body retaining spring for damage if the spring is defective, replace the spring. 7. Click the cylinder body retaining spring in position and make sure that: ● The two ends of spring click correctly into the locating holes of the cylinder body. ● The spring is in the correct position against the lugs of the torque member.

Locating holes Torque member lug

NBR292

Removal WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials. CAUTION: Suspend caliper assembly with wire to avoid stretching the brake hose.

Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly.

NBR289

Disassembly WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with dust seal with compressed air. 2. Remove piston seal with a suitable tool.

NBR294

Inspection — Caliper CYLINDER BODY Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil. ●

BR-29

FRONT DISC BRAKE Inspection — Caliper (Cont’d)

SR20DE - M/T

PISTON CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

GUIDE PIN, BOLT, AND RETAINING SPRING Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

BR-30

FRONT DISC BRAKE Inspection — Rotor RUBBING SURFACE Check rotor for roughness, cracks or chips.

RUNOUT

SBR936A

1. Secure rotor to wheel hub with at least two nuts (M12 × 1.25). 2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to section FA. Maximum runout: 0.07 mm (0.0028 in) 3. If the runout is out of specification, find minimum runout position as follows: a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor tho wheel hub with nuts. c. Measure runout. d. Repeat steps a. to c. so minimum runout position can be found. 4. If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent).

THICKNESS Rotor repair limit: Standard thickness 22 mm (0.87 in) Minimum thickness 20.0 mm (0.787 in) Thickness variation (At least 8 positions) Maximum 0.02 mm (0.0008 in)

SBR944A

Assembly Dust seal

Piston seal Piston

Cylinder body

CAUTION: Always use new piston seal. 1. Insert new piston seal into groove in cylinder body 2. With dust seal fitted to piston, insert dust seal into groove on cylinder body and install piston. 3. Properly secure dust seal.

SBR574

BR-31

FRONT DISC BRAKE Installation

.

Protrusions

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Install brake hose to caliper securely. 2. Install all parts and secure all bolts. 3. Bleed air. Refer to “Bleeding Brake System” BR-8.

NBR160

Protrusions

NBR298

BR-32

REAR DISC BRAKE TYPE 1 Component SEC. 440 29 p

p2 19 p

p3 p 11

31 - 38 (3.2 - 3.8, 23 - 28)

21 p 22 p

p R

23 p 24 p

Stopper bolt

B p 25 26 p p

12 p

p 4

p p P

p 27

10 - 12 (1.0 - 1.2, 7 - 9)

p1 22 - 32 (2.3 - 3.2, 17 - 23)

R p

20 p

13 p

R p

to sliding portion

R p

14 p

5

p6

15 p

16 p

17 p 18 p

28 p

R p p B

R p

p7 p8 38 - 52 (3.9 - 5.3, 28 - 38)

p9

P p 10 p

: Do not re-use P p

: N·m (kg-m, ft-lb)

p B p P p R

: Rubber grease point : Brake fluid point : PBC (Poly Butyl Cuprysil) grease or silicone-based grease point

NBR366

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

Cable guide Cylinder Toggle lever Pin Pin boot Torque member Inner shim Inner pad Outer pad Outer shim

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Strut O-ring Push rod Key plate Retaining washer Spring Spring cover Snap ring B Piston seal Snap ring A

21. 22. 23. 24. 25. 26. 27. 28. 29.

Washer Wave washer Washer Bearing Adjuster Cup Piston Piston boot Sleeve

Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ● If shims are rusted or show peeling of rubber coat, replace them with new shims.

BR-33

REAR DISC BRAKE TYPE 1 Pad Replacement (Cont’d) ●

●

NBR192

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “CHECK AND ADJUSTMENT”, BR-7.

1. Remove master cylinder reservoir cap. 2. Remove brake cable mounting bolt and lock spring. 3. Release parking brake control lever, then disconnect cable from the caliper. 4. Remove upper pin bolt. 5. Open cylinder body downward. Then remove pads inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)

Wire

SBR916C

6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown. Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

SBR641

7. Adjust the piston to the right angle as shown in the figure. Assembly to the right angle

Piston

Alignment position of disc pad’s concave

Concave portion NBR374

BR-34

REAR DISC BRAKE TYPE 1 Pad Replacement (Cont’d) 8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 9. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.

Concave portion

Convex portion

NBR375

Removal

NBR167

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. 1. Remove brake cable mounting bolt and lock spring. 2. Release parking brake control lever, then disconnect cable from the caliper. 3. Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

Disassembly 1. Remove piston by turning it counterclockwise with long nose pliers or suitable tool.

SBR646

2. Pry off snap ring A from piston with suitable pliers and remove adjusting nut.

Ring “A”

SBR889

BR-35

REAR DISC BRAKE TYPE 1 Disassembly (Cont’d) 3. Disassemble cylinder body. a. Pry off snap ring B with suitable pliers, then remove spring cover, spring and retaining washer. b. Remove key plate, push rod, O-ring and strut.

SBR088B

c. Remove piston seal. Be careful not to damage cylinder body.

SBR656

4. Remove return spring, toggle lever and cable guide. Return spring Stopper bolt

Lever SBR767E

Inspection Caliper CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body ●

●

Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member Check for wear, cracks or other damage. Replace if necessary.

Piston CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

BR-36

REAR DISC BRAKE TYPE 1 Inspection (Cont’d) Pin and Pin Boot Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

Rotor Rubbing Surface Check rotor for roughness, cracks or chips.

Runout

SBR219C

1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to RA section (“REAR WHEEL BEARING”, “On-vehicle Service”). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)

Thickness Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)

Assembly 1. Insert cam with depression facing towards open end of cylinder. Cam Seal Sleeve

NBR367

2. Generously apply rubber grease to strut and push rod to make insertion easy.

O-ring Strut

R p

Push rod Rubber grease

SBR248B

BR-37

REAR DISC BRAKE TYPE 1 Assembly (Cont’d) 3. Install rod, push rod and key plate. Key plate

Push rod

Rod

SBR754E

4. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.

Concave portion Convex portion

SBR893

5. Install retaining washer, spring, spring cover and snap ring B with suitable press and drift. Ring B Spring cover

Spring

Commercial service tool

Retaining washer SBR869CB Push Ring B Spring cover Tool Spring

Retaining washer SBR879-B

6. Install cup in the specified direction.

Adjusting nut SBR892

BR-38

REAR DISC BRAKE TYPE 1 Assembly (Cont’d) 7. Install cup adjuster, bearing, washers and snap ring A with a suitable tool.

Ring A Washer Wave washer Washer Ball bearing Adjuster Cup Piston SBR755E

8. Insert piston seal into groove on cylinder body. 9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.

SBR646

10. Fit toggle lever, return spring and cable guide. Return spring Stopper bolt

Lever SBR767E

11. Adjust the piston to the right angle as shown in the figure. Assembly to the right angle

Piston

Alignment position of disc pad’s concave

Concave portion NBR374

Installation

Concave portion

Convex portion

NBR375

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. 1. Install caliper assembly. ● As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 2. Install brake hose to caliper securely. 3. Install all parts and secure all bolts. 4. Bleed air. Refer to “Bleeding Brake System”, BR-8

BR-39

REAR DISC BRAKE TYPE 2 Component

NBR440

1. 2. 3. 4.

Cylinder body Pin Pin boot Torque member

5. 6. 7.

Inner shim Inner pad OUter pad

8. Outer shim 9. Bleed valve 10. Connecting bolt

NOTE: The cylinder body cannot be disassembled.

Pad Replacement WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ● When cylinder body is open, do not depress brake pedal because piston will pop out. ● Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ● If shims are rusted or show peeling of rubber coat, replace them with new shims. ● It is not necessary to remove connecting bolt except for replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7.

BR-40

REAR DISC BRAKE TYPE 2 Pad Replacement (Cont’d) 1. Remove master cylinder reservoir cap. 2. Remove brake cable lock spring. 3. Release parking brake control lever, then disconnect cable from the caliper. 4. Remove upper pin bolt.

NBR423

5. Open cylinder body downward. Then remove pad inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)

NBR426

6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown. Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

SBR641

7. Adjust the piston to the right angle as shown in the figure.

NBR374

8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 9. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.

NBR375

BR-41

REAR DISC BRAKE TYPE 2 Removal

NBR427

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. 1. Remove brake cable lock spring. 2. Release parking brake control lever, then disconnect cable from the caliper. 3. Remove torque member fixing bolts and connecting bolt. 4. Remove brake hose connecting bolt. 5. Plug off the brake hose and cylinder body to prevent air entering the system. CAUTION: Care should be taken as not to let: ● Air enter the cylinder body and brake hose. ● Brake fluid spill from the cylinder body and brake hose.

Disassembly Remove pin bolts and pins. NOTE: Cylinder body can not be disassembled.

Inspection CALIPER CAUTION: Do not drain any brake fluid from cylinder body. Cylinder body can not be disassembled.

Cylinder Body Check cylinder body for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.

Torque Member Check for wear, cracks or other damage. Replace if necessary.

Pin and Pin Boot Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

BR-42

REAR DISC BRAKE TYPE 2 Inspection (Cont’d) ROTOR Rubbing Surface Check rotor for roughness, cracks or chips.

Runout

SBR219C

1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to AX section (“REAR WHEEL BEARING”, “On-vehicle Service”). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)

Thickness Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)

Installation

NBR374

CAUTION: ● Refill with new brake fluid “DOT 4”. ● Never reuse drained brake fluid. ● Do not drain (factory) filled brake fluid from (new) caliper assemblies. 1. Install caliper assembly. ● As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member. 2. Remove the plug from the cylinder body and brake hose. CAUTION: Care should be taken as not to let: ● Air enter the cylinder body and brake hose. ● Brake fluid spill from the cylinder body and brake hose. 3. Install brake hose to caliper securely. 4. Install all parts and secure all bolts. 5. Bleed air. Refer to “Bleeding Brake System”, BR-8.

NBR375

BR-43

REAR DRUM BRAKE Components

SBR616E

1. 2. 3. 4. 5.

Boot Piston Piston cap Spring Wheel cylinder

6. 7. 8. 9. 10.

Shoe hold-down pin Plug Brake drum Shoe hold-down spring Adjuster

11. 12. 13. 14. 15.

Retainer ring Return spring (Upper) Return spring (Lower) Spring Toggle lever

Removal WARNING: Clean brake lining with a vacuum dust collector to minimize the hazard of airborne materials. CAUTION: Make sure parking brake lever is completely released.

BR-44

REAR DRUM BRAKE Removal (Cont’d) 1. Release parking brake lever fully, then remove drum. If drum is hard to remove, the following procedures should be carried out. a. Remove plug. To make shoe clearance, push shoe holddown spring to free toggle lever.

SBR617E

b. Install two bolts as shown. Tighten the two bolts gradually.

SBR020A

2. After removing retainer, remove spring by rotating shoes. ● Be careful not to damage wheel cylinder piston boots. ● Be careful not to damage parking brake cable when separating it. 3. Remove adjuster. 4. Disconnect parking brake cable from toggle lever.

SBR214B

5. Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe.

SBR329C

Inspection — Wheel Cylinder ● ●

Check wheel cylinder for leakage. Check for wear, damage and loose conditions. Replace if any such condition exists.

SBR330C

BR-45

REAR DRUM BRAKE Wheel Cylinder Overhaul ● ●

Check all internal parts for wear, rust and damage. Replace if necessary. Pay attention so as not to scratch cylinder when installing pistons.

SBR215B

Inspection — Drum

● ● ● SBR022A

Maximum inner diameter: 204.5 mm (8.05 in) Maximum out-of-round: 0.03 mm (0.0012 in) Contact surface should be fine finished with No. 120 to 150 emery paper. Using a drum lathe, resurface brake drum if it shows scoring, partial wear or stepped wear. After brake drum has been completely reconditioned or replaced, check drum and shoes for proper contact pattern.

Inspection — Lining Check lining thickness. Standard lining thickness: 4.5 mm (0.177 in) Lining wear limit: 1.5 mm (0.059 in)

SMA849B

Installation Always perform shoe clearance adjustment. Refer to BR-49. ● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7. 1. Fit toggle lever to brake shoe with retainer ring. 2. Apply brake grease to the contact areas shown at left. ●

SBR618E

BR-46

REAR DRUM BRAKE Installation (Cont’d)

SBR619E

3. Shorten adjuster by rotating it. ● To tighten loosened brake shoes, first, insert a screw driver in the direction shown in the left. Then, move the adjuster in the direction shown by the arrow while disengaging the tooth contact. Never tap the area E. 4. Connect parking brake cable to toggle lever. 5. Install all parts. Be careful not to damage wheel cylinder piston boots. 6. Check all parts are installed properly. Pay attention to direction of adjuster assembly. 7. Install brake drum. 8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to “Bleeding Brake System”, BR-8. 9. Adjust parking brake. Refer to BR-49.

BR-47

PARKING BRAKE CONTROL

NBR441

Removal and Installation 1. 2. 3. 4. 5.

To remove parking brake cable, first remove center console. Disconnect warning lamp connector. Remove adjusting nut. Remove bolts and nuts securing parking brake cable. Remove parking brake device.

Adjusting nut Warning lamp connector NBR171

6. Remove cable mounting bracket and lock plate (disc brake only). For drum brake models, refer to “Removal”, “REAR DRUM BRAKE”, BR-44.

NBR163

BR-48

PARKING BRAKE CONTROL Inspection 1. Check control lever for wear or other damage. Replace if necessary. 2. Check wires for discontinuity or deterioration. Replace if necessary. 3. Check warning lamp and switch. Replace if necessary. 4. Check parts at each connecting portion and, if found deformed or damaged, replace the parts.

Adjustment

Stopper bolt

Lever

Before or after adjustment, pay attention to the following points. ● Make sure the toggle lever of the rear disc brakes returns to stopper, when the parking lever is released. ● There is no drag when parking brake lever is released. ● Vehicle is unladen.

SBR768E

1. Adjust clearance between shoe and drum or pad and rotor as follows: a. Release parking brake lever and loosen adjusting nut. b. Depress brake pedal fully at least 10 times with engine running.

2. Pull control lever 10 times or more to make a lever stroke of 203.5 mm (8.01 in). At 6 - 8 notches, adjust the parking brake cable by turning the adjusting nut.

Adjusting nut

SBR756E

3. Pull control lever with the specified amount of force. Check lever stroke and ensure smooth operation. Number of notches 6-8 4. Bend warning lamp switch plate to ensure: ● Warning lamp comes on when lever is lifted “A” notches. ● Warning lamp goes out when lever is fully released. Number of “A” notches: 1

196 N (20 kg, 44 lb)

SBR033A

BR-49

ANTI-LOCK BRAKE SYSTEM Purpose The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided. The ABS: 1) Provides improved steering control during braking (by preventing front wheel lock). 2) Provides improved vehicle stability and skid prevention during braking (by avoiding rear wheel lock).

Operation ● ●

●

When the vehicle speed is less than 10 km/h (6 mph) this system does not work. The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning light for 1 second after turning the ignition switch to the “ON” position. The system performs another test the first time the vehicle reaches 6 km/h (4 mph). A mechanical noise may be heard as the ABS performs a self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning light will come on. During ABS operation, a mechanical noise may be heard. This is a normal operating condition.

ABS Hydraulic Circuit

Rear LH wheel

Front RH wheel

Front LH wheel

Rear RH wheel

NBR259 1 p 2 p 3 p

Inlet solenoid valve Outlet solenoid valve Reservoir

4 p 5 p

6 p 7 p

Pump Motor

BR-50

Bypass check valve Damper

ANTI-LOCK BRAKE SYSTEM System Components

Warning light Brake tube connector

Actuator

Rear wheel sensors

Control unit

Front wheel sensors

NBR260

System Description

Control unit Magnet . Sensor (proximity detector) Magnetic flux

SENSOR

Low carbon steel Coil Sensor rotor

Tooth

Moving time of one tooth

V: Induced electromotive force

SBR124B

The sensor unit consists of a gear-shaped sensor rotor and an electro-magnetic proximity detector. The proximity detector (“pick-up”) contains a bar magnet around which a coil is wound. The detector is installed on the back side of the brake rotor. An alternating voltage is generated in the coil of the proximity detector as each tooth of the rotor cuts the magnetic field of the detector core. The frequency and amplitude of the voltage increases in proportion to the rotational speed of the rotor.

CONTROL UNIT

ABS warning light NBR284

The control unit determines the wheel rotating speed from the signal sent from the sensor, a corresponding control signal is then output from the control unit in the form of a DC current to the actuator solenoid valve. The ABS control unit also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle’s brake system reverts to normal operation.

BR-51

ANTI-LOCK BRAKE SYSTEM System Description (Cont’d) ABS ACTUATOR AND ELECTRIC UNIT ABS control unit ABS control unit harness connector

.

ABS actuator

NBR297

The ABS actuator and electric unit contains: ● An electric motor and pump ● Two relays ● Eight solenoid valves, each inlet and outlet for — LH front — RH front — Rear LH/RH ● ABS control unit This component controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit can not be disassembled and has to be serviced as an assembly.

ABS actuator operation Inlet solenoid valve

Outlet solenoid valve

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is directly transmitted to wheel cylinder via the inlet solenoid valve.

Pressure hold

ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the wheel cylinder brake fluid pressure.

Pressure decrease

ON (Closed)

ON (Open)

Wheel cylinder brake fluid is sent to reservoir via the outlet solenoid valve. Then it is pushed up to the master cylinder by pump.

Pressure increase

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is transmitted to wheel cylinder.

Normal brake operation

ABS operation

BR-52

ANTI-LOCK BRAKE SYSTEM Removal and Installation CAUTION: Be careful not to damage sensor edge and sensor rotor teeth. When removing the front or rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly and move it away. Failure to do so may result in damage to the sensor or wiring making it inoperative.

FRONT WHEEL SENSOR

18 - 24 (1.8 - 2.4, 13 - 18)

: N·m (kg-m, ft-lb)

NBR176

REAR WHEEL SENSOR

25 - 33 (2.6 - 3.4, 18 - 24)

: N·m (kg-m, ft-lb) NBR296

BR-53

ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) SENSOR ROTOR

Front sensor rotor

Removal 1. Remove the drive shaft and rear wheel hub. Refer to FA, RA section (“Drive Shaft”, FRONT AXLE” and “Wheel Hub”, REAR AXLE”). 2. Remove the sensor rotor using suitable puller, drift and bearing replacer.

Drive shaft

SBR984C

Rear sensor rotor

Suitable drift

SBR873CA

Installation

Front sensor rotor

Install the sensor rotor. For front sensor rotor, use hammer and wooden block. For rear sensor rotor, use suitable drift and press. ● Always replace sensor rotor with new one. ● Ensure sensor rotor is completely flush with surface indicated on drive shaft.

Flush

Wooden block NBR196

●

Press

Rear sensor rotor

Pay attention to the flush position of rear sensor rotor as shown in figure. h: −0.3 to +0.3 mm (−0.012 to +0.012 in)

Suitable drift

h

Sensor rotor Wheel hub

.

NBR197

ABS control unit harness connector ABS actuator

CONTROL UNIT Location: Built-in ABS actuator. When disconnecting the harness connector, pull the lever as shown figure.

PULL

X 1 ABS control unit

X NBR261

BR-54

ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) ABS ACTUATOR

Front master cylinder secondary

To front wheel cylinder (RH)

To front wheel cylinder (LH)

To rear wheel cylinder (LH)

From master cylinder primary To rear wheel cylinder (RH)

10 - 14 (1.0 - 1.4, 7.2 - 10.1)

ABS actuator & electric control unit

Actuator/ground cable

Unlock

Lock

10.8 - 14.7 (1.1 - 1.5,8.0 - 10.8)

7-9 (0.7 - 0.9, 5.1 - 6.5)

FRONT

11 - 15 (1.1 - 1.5, 8.0 -10.8)

Actuator bracket

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) NBR262

BR-55

ANTI-LOCK BRAKE SYSTEM Removal and Installation (Cont’d) 1. Disconnect battery cable. 2. Drain brake fluid. Refer to BR-7

ABS control unit harness connector ABS actuator

3. Unlock the slider then disconnect the electrical harness connectors from ABS control unit. 4. Identify each brake pipe with corresponding actuator port hole and mark them accordingly.

PULL

ABS control unit NBR261

5. Disconnect brake pipes and move them away from actuator. Do not force brake pipes so as to kink them or bend them excessively. Ensure that brake fluid does not come into contact with any parts. 6. Loosen/remove mounting nuts between actuator and bracket.

NBR249

CAUTION: After installation, pay attention to the following points: ● Refill brake fluid and bleed air. Refer to “CHECK AND ADJUSTMENT”, BR-7 and “BLEEDING BRAKE SYSTEM”, BR-8, respectively.

ABS actuator

.

10.8 - 14.7 N·m (1.1 - 1.5 Kg-m, 8.0 - 10.8 ft-lb)

● The installation procedure is as follows: 1. Install actuator on bracket without tightening fixings. 2. Assemble brake tubes to actuator without tightening tube nuts. Ensure that correct tubes are connected to each port. 3. Fully tighten actuator and bracket fixings to specified torque. 4. Fully tighten flare nuts to specified torque, BR-10. 5. Secure ABS control unit harness connector and battery cable.

NBR171

BR-56

TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair INTRODUCTION

SEF233G

SEF234G

The ABS system has an electronic control unit to control major braking functions. The control unit accepts input signals from sensors and utilises the data to instantly drive the actuators. It is essential that both input and output signals are correct and stable. It is also important to check for conventional problems: such as air leaks in booster lines, lack of brake fluid, or other problems with the brake system. It is much more difficult to diagnose a problem that occurs intermittently rather than catastrophically. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the unnecessary replacement of good parts. A visual check may not be sufficient to find the cause of the problems, so a road test should also be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a ABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for “conventional” problems first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle.

BR-57

TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d) WORK FLOW CHECK IN

F

Reference item

H

LISTEN TO CUSTOMER COMPLAINTS

H

INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELARED TO EACH SYMPTOM AND NOTE

F

Go to MALFUNCTION CODE/SYMPTOM CHART, BR-76.

F

Go to Preliminary Check, BR-59.

F

Go to Self-diagnosis, BR-67.

H

CHECK FOR ANY SERVICE BULLETINS.

H

E ELIMINATE GOOD SYSTEMS AND GOOD PARTS

Not self-diagnostic item

Self-diagnostic item H DETERMINE MALFUNCTIONING CIRCUIT(S) OR PART(S).

Self-diagnosis ●

H H ELIMINATE GOOD PART(S), HARNESS(ES) OR CONNECTOR(S) THROUGH ELECTRICALLY TESTING

Malfunctioning harness(es) and connector(s)

F

Malfunctioning parts

H INSPECTION OF EACH COMPONENT

H

H REPAIR

REPAIR OR REPLACE

H NG

●

Go to Diagnostic Procedure(s) 6 - 12, BR-85. Go to Component Parts and Harness Connector Location, BR-60.

H FINAL CHECK OK H

CHECK OUT

BR-58

F

Go to Diagnostic Procedure(s) 1 - 5, BR-77.

TROUBLE DIAGNOSES Preliminary Check Check brake fluid level in reservoir tank. -----------------------------------------------------------------------------------------------------------------------------------------------------Low fluid level may indicate brake pad wear or leakage from brake line.

MAX.

MIN.

NBR141

H

Check brake line for leakage.

NG

E

Repair.

OK F H

Check brake booster for operation and air tightness. Refer to BR-18.

NG

E

Replace.

OK F H

Check brake pads and rotor. Refer to BR-23, 26, 33. SBR389C

NG

E

Replace.

OK H

Check brake fluid level in reservoir tank. NG

E

Fill up brake fluid.

OK H

Check warning lamp activation. When ignition switch is turned on, warning lamp turns on.

NG

E

Check fuse, warning lamp bulb and warning lamp circuit.

OK SBR058C

H

Check warning lamp for deactivation. When ignition switch is turned on, warning lamp turns on, then deactivates after 1 second.

.

NG

E

Go to Self-diagnosis, BR-67 and BR-70.

E

Go to Self-diagnosis, BR-67 and BR-70.

OK H

Drive vehicle at 30 km/h (19 mph) for at least one minute. H SBR059C

Ensure warning lamp remains off while driving. OK H

END

ABS warning light NBR284

BR-59

NG

TROUBLE DIAGNOSES Component Parts and Harness Connector Location

Warning light Brake tube connector

ABS actuator and electric unit

Rear wheel sensors Rear left wheel sensor connector Rear right wheel sensor connector Front wheel sensors Front left wheel sensor connector Front right wheel sensor connector

E17

Sensor

.

E78

Sensor

E57

B33 B32

Rear left wheel sensor connector . Rear right wheel Rear tire sensor connector

NBR285

BR-60

TROUBLE DIAGNOSES Circuit Diagram for Quick Pinpoint Check

YBR228

BR-61

TROUBLE DIAGNOSES Wiring Diagram — ABS — MODELS WITH SELF-DIAGNOSIS FUNCTION IGNITION SWITCH ON or START

BATTERY

FUSE BLOCK (J/B)

Refer to EL-POWER.

: LHD models

: CVT models

: RHD models

: M/T models

STOP LAMP SWITCH DEPRESSED RELEASED COMBINATION METER (ABS WARNING LAMP)

FUSE BLOCK (J/B)

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

TCM (TRANSMISSION CONTROL MODULE)

DATA LINK CONNECTOR

Refer to las page (Foldout page).

YBR208

BR-62

TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d) MODELS WITHOUT SELF-DIAGNOSIS FUNCTION

YBR229

BR-63

TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)

YBR230

BR-64

TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)

YBR231

BR-65

TROUBLE DIAGNOSES Wiring Diagram — ABS — (Cont’d)

YBR232

BR-66

TROUBLE DIAGNOSES Self-diagnosis (Only models with data link connector terminal No. 8) FUNCTION ●

When a problem occurs in the ABS, the warning lamp on the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on “Data Link Connector for CONSULT-II”. The location of the malfunction is indicated by the warning lamp flashing.

SELF-DIAGNOSIS PROCEDURE .

DATA link connector for CONSULT-II

Drive vehicle over 30 km/h (19 mph) for at least one minute. (Ground terminal 8 with a suitable harness.)

H

Turn ignition switch to the “LOCK” position. H

NBR295

Ground terminal “8” of “DATA LINK CONNECTOR for CONSULT-II” with a suitable harness. H

Turn ignition switch to “ON” position while grounding terminal “8”. Do not depress brake pedal. H

After 3.0 seconds, the warning lamp starts flashing to indicate the malfunction code No. (See NOTE.) ABS warning light NBR284 .

DATA link connector for CONSULT-II (Disconnect the harness)

H

Verify the location of the malfunction with the malfunction code chart. Refer to BR-69. Then make the necessary repairs following the diagnostic procedures. H

After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-68. H NBR305

Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.

H

Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete. H

A p

BR-67

NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from off to on, the indication starts flashing again.

TROUBLE DIAGNOSES Self-diagnosis (Only models with data link connector terminal No. 8) (Cont’d) A p

H

Check warning lamp for deactivation after driving vehicle over 30 km/h (19 mph) for at least one minute. H

After making certain that warning lamp does not come on, test the ABS in a safe area to verify that it functions properly.

HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes) ● ● ●

●

üüüDetermine the code No. by counting the number of times the warning lamp flashes on and off. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). The malfunction code chart is given on the next page.

Example: Code No. 32 REAR SENSOR SHORT-CIRCUIT Start code: 12 Tens digits Units digits ON Warning lamp OFF 3.0

0.6

0.9

0.3

0.3

CODE No. 32 Tens digits

3.3

0.3

ON

0.6 0.6

0.6

0.6

0.6

Units digits

0.9

0.3 0.3 0.3 Unit: Second

IGN OFF

SBR457C

Self-diagnosis completed ABS warning lamp

ON OFF Check terminal

Open (disconnect) Ground More than 1 sec 12.5 sec Malfunction code memory erased ABR256

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (Malfunction codes) 1. Disconnect the check terminal from ground (ABS warning lamp will stay lit). 2. Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed. 3. Perform self-diagnosis again. Refer to BR-67. Only the startcode should appear, no malfunction codes.

BR-68

Trouble Diagnosis — General Description CONSULT-II CONSULT-II APPLICATION TO ABS SELF-DIAGNOSTIC RESULTS

DATA MONITOR

ACTIVE TEST

Front right wheel sensor

X

X

—

Front left wheel sensor

X

X

—

Rear right wheel sensor

X

X

—

Rear left wheel sensor

X

X

—

Stop lamp switch

—

X

—

Front right inlet solenoid valve

X

X

X

Front right outlet solenoid valve

X

X

X

Front left inlet solenoid valve

X

X

X

Front left outlet solenoid valve

X

X

X

Rear right inlet solenoid valve

X

X

X

Rear left inlet solenoid valve

X

X

X

Rear right outlet solenoid valve

X

X

X

Rear left outlet solenoid valve

X

X

X

Actuator solenoid valve relay

X

X

—

Actuator motor relay (ABS MOTOR is shown on the Data Monitor screen.)

X

X

X

ABS warning lamp

—

X

—

Battery voltage

X

X

—

Control unit

X

—

—

ITEM

X: Applicable —: Not applicable

ECU part number mode Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU.

BR-69

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure SELF-DIAGNOSIS PROCEDURE Fuses

Data link connector

1) Turn ignition switch to the “LOCK” position. 2) Connect CONSULT-II to Data Link Connector.

.

H

NEF125A

1) Start engine. 2) Drive vehicle over 30 km/h (19 mph) for at least one minute. H

C2NCS01

●

1) Stop vehicle with engine running and touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “SELF-DIAG RESULTS”. The screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction. H

.

MALFUNCTION REPAIR ----------------------------------------------------------------------------------------------------------------------------------------------------Make the necessary repairs following the diagnostic procedures.

CVT

C2SSE01 H

After repairing the malfunctions, erase the self-diagnostic results stored in the control unit by touching “ERASE”. H

Check warning lamp for deactivation after driving vehicle over 30 km/h (19 mph) for at least one minute. C2SDM01

H

End

Note: “SELF-DIAG RESULTS” screen shows the detected malfunction and the times of ignition switch on and off after it occurred.

C2SDR01

BR-70

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) SELF-DIAGNOSTIC RESULTS MODE Diagnostic item FR RH SENSOR★ [OPEN] FR LH SENSOR★ [OPEN] RR RH SENSOR★ [OPEN] RR LH SENSOR★ [OPEN] FR RH SENSOR★ [SHORT] FR LH SENSOR★ [SHORT] RR RH SENSOR★ [SHORT] RR LH SENSOR [SHORT] ABS SENSOR★ [ABNORMAL SIGNAL] FR RH IN ABS SOL [OPEN] FR LH IN ABS SOL [OPEN] RR RH IN ABS SOL [OPEN] RR LH IN ABS SOL [OPEN] FR RH IN ABS SOL [SHORT] FR LH IN ABS SOL [SHORT] RR RH IN ABS SOL [SHORT] RR LH IN ABS SOL [SHORT] FR RH OUT ABS SOL [OPEN] FR LH OUT ABS SOL [OPEN] RR RH OUT ABS SOL [OPEN] RR LH OUT ABS SOL [OPEN] FR RH OUT ABS SOL [SHORT] FR LH OUT ABS SOL [SHORT] RR RH OUT ABS SOL [SHORT] RR LH OUT ABS SOL [SHORT] ABS ACTUATOR RELAY [ABNORMAL] ABS MOTOR RELAY [ABNORMAL] BATTERY VOLT [VB-LOW] CONTROL UNIT

Diagnostic item is detected when . . .

Diagnostic procedure

● ● ●

Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.) Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.) Circuit for rear right sensor is open. (An abnormally high input voltage is entered.) Circuit for rear left sensor is open. (An abnormally high input voltage is entered.) Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.) Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.) Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.) Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.) Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.) Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front right outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front left outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear right outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear left outlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Actuator solenoid valve relay is ON, even control unit sends off signal. Actuator solenoid valve relay is OFF, even control unit sends on signal. Circuit for actuator motor is open or shorted. Actuator motor relay is stuck. Circuit for actuator is open or shorted.

●

Power source voltage supplied to ABS control unit is abnormally low.

4

●

Function of calculation in ABS control unit has failed.

5

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3

★: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does not indicate a malfunction. Only in the case of the short-circuit after repair the ABS warning lamp also illuminates when the ignition switch is turned “ON”. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute as specified in “SELF-DIAGNOSIS PROCEDURE”, BR-70. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven.

BR-71

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) DATA MONITOR PROCEDURE 1) Turn ignition switch to the off position. 2) Connect CONSULT-II to Data Link Connector. 3) Turn ignition switch to the ON position. H

1) Touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “DATA MONITOR”. C2NCS01 H

1) Select “SELECT MONITOR ITEM”. H

Carry out the monitor test under the condition as described in page BR-73.

C2SSE01

C2SDM01

C2SMI01

BR-72

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) DATA MONITOR MODE MONITOR ITEM

CONDITION

SPECIFICATION

FR RH SENSOR FR LH SENSOR REAR RH SENSOR REAR LH SENSOR

Drive vehicle. (Each wheel is rotating.)

Wheel speed signal Almost the same speed as speedometer.

STOP LAMP SW

Brake is depressed.

Depress the pedal: ON Release the pedal: OFF

FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR RH IN SOL RR RH OUT SOL RR LH IN SOL RR LH OUT SOL

1. Drive vehicle at speeds over 30 km/h (19 mph) for at least one minute. 2. Engine is running.

Operating conditions for each solenoid valve are indicated. ABS is not operating: OFF

MOTOR RELAY

ABS is not operating: OFF ABS is operating: ON

ACTUATOR RELAY

Ignition switch in the “ON” position (Engine stops): OFF Engine running: ON

WARNING LAMP BATTERY VOLT

Ignition switch is set to the “ON” position or engine is running.

Warning lamp is turned on: ON Warning lamp is turned off: OFF Power supply voltage for control unit

BR-73

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) ACTIVE TEST PROCEDURE ● ●

When conducting Active test, vehicle must be stationary. When ABS warning lamp stays on, never conduct Active test.

1) Turn ignition switch to the “LOCK” position. 2) Connect CONSULT-II to Data Link Connector. 3) Start engine.

C2NCS01

H

1) Touch “START” on CONSULT-II screen. 2) Touch “ABS”. 3) Touch “ACTIVE TEST”. H

.

1) Select active test item by touching screen. 2) Touch “START”.

CVT

H

Carry out the active test by touching screen key. C2SSE01

C2SDM01

C2STI01

C2FRS01

BR-74

Trouble Diagnosis — General Description CONSULT-II Inspection Procedure (Cont’d) ACTIVE TEST MODE TEST ITEM

CONDITION

JUDGEMENT Brake fluid pressure control operation

FR RH SOLENOID FR LH SOLENOID RR RH SOLENOID RR LH SOLENOID

Engine is running.

UP (Increase): KEEP (Hold): DOWN (Decrease):

IN SOL

OUT SOL

OFF ON ON

OFF OFF ON

ABS actuator motor ON: Motor runs (ABS motor relay ON) OFF: Motor stops (ABS motor relay OFF)

ABS MOTOR

Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows ON.)

Ground Circuit Check ABS ACTUATOR AND ELECTRIC UNIT GROUND ● ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

Check resistance between ABS actuator and electric unit connector terminals and ground. Resistance: approximately 0Ω

YBR170

BR-75

Trouble Diagnosis — General Description Malfunction Code/Symptom Chart MODELS WITH SELF-DIAGNOSIS FUNCTION Code No. (No. of LED flashes)

Malfunctioning part

Reference page

12

Self-diagnosis could not detect any malfunctions.

—

18

Sensor rotor

BR-77

21

Front right sensor (open-circuit)

BR-77

22

Front right sensor (short-circuit)

BR-77

25

Front left sensor (open-circuit)

BR-77

26

Front left sensor (short-circuit)

BR-77

31

Rear right sensor (open-circuit)

BR-77

32

Rear right sensor (short-circuit)

BR-77

35

Rear left sensor (open-circuit)

BR-77

36

Rear left sensor (short-circuit)

BR-77

41

Actuator front right outlet solenoid valve

BR-79

42

Actuator front right inlet solenoid valve

BR-79

45

Actuator front left outlet solenoid valve

BR-79

46

Actuator front left inlet solenoid valve

BR-79

51

Actuator rear right outlet solenoid valve

BR-79

52

Actuator rear right inlet solenoid valve

BR-79

55

Actuator rear left outlet solenoid valve

BR-79

56

Actuator rear left inlet solenoid valve

BR-79

57*

Power supply (Low voltage)

BR-83

61

Actuator motor or motor relay

BR-81

63

Solenoid valve relay

BR-79

71

Control unit

BR-84

ABS warning lamp stays on when ignition switch is turned on.

Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil

BR-90

ABS warning lamp stays on, during self-diagnosis.

Control unit

ABS warning lamp does not come on when ignition switch is turned on.

Fuse, warning lamp bulb or warning lamp circuit Control unit

ABS warning lamp does not come on during self-diagnosis.

Control unit

—

BR-88

—

Pedal vibration and noise

—

BR-87

Long stopping distance

—

BR-86

Unexpected pedal action

—

BR-86

ABS does not work.

—

BR-87

ABS works frequently.

—

BR-85

*: Under voltage that is too low, the control unit disable the ABS. It does not set the ABS in fail-safe condition. Instead, the ABS becomes a conventional brake system. After the power supply has resumed, the warning lamp goes off, making it possible for the ABS to be re-engaged.

BR-76

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Front RH

Front LH

Rear RH

Rear LH

Diagnostic Procedure 1 (Wheel sensor or rotor) (Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18 for models with self-diagnosis function)

ABS actuator and electric unit Wheel sensor connectors (sensor side) Rear LH Front LH Front RH

Rear RH NBR420

INSPECTION STARTS 1. Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No. Check terminals for damage or loose connections. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again?

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

No

E

Inspection end

Yes H

NBR414

Front sensor

Rear sensor

YBR173

CHECK WHEEL SENSOR ELECTRICAL. 1. Disconnect ABS actuator and electric unit connector. 2. Check resistance between ABS actuator and electric unit connector E78 (body side) terminals. Code No. 21 or 22 (Front RH wheel) Terminals p 11 and p 12 Code No. 25 or 26 (Front LH wheel) Terminals p 9 and p 10 Code No. 31 or 32 (Rear RH wheel) Terminals p 13 and p 15 Code No. 35 or 36 (Rear LH wheel) Terminals p 7 and p 8 Resistance: Front 1.44 - 1.76 kΩ Rear 1.44 - 1.76 kΩ

OK

p

E A

(Go to next page.)

NG H

CHECK WHEEL SENSOR. Check each sensor for resistance. Resistance: Front 1.44 - 1.76 kΩ Rear 1.44 - 1.76 kΩ NG

H

REPLACE. Replace wheel sensor.

BR-77

OK

E

Check the following. ● Harness connectors E78

Harness for open or short between wheel sensor connectors and ABS actuator and electric unit If NG, repair harness or connectors.

●

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 1 (Wheel sensor or rotor) (Cont’d) Front sensor

A p

Feeler gauge

Note

Note

H

CHECK TYRE. Check for inflation pressure, wear and size of each tyre.

NG

E

Adjust tyre pressure or replace tyre(s).

E

Clean sensor fixing portion, or replace sensor.

OK Sensor

Note Rotor Sensor

Feeler gauge

H

CHECK WHEEL BEARING Check wheel bearing axial end play and clearance between sensor and rotor. Clearance Front 0.1 - 1.1 mm (0.004 - 0.043 in) Rear 0.536 - 1.551 mm (0.021 - 0.061 in)

NG

OK NBR391

Note

Note

H

CHECK SENSOR ROTOR. Check sensor rotor for teeth damage.

NG

E

Replace sensor rotor.

OK H

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

Note: Wheel position should be indentified by code numbers except code No. 18 (sensor rotor).

BR-78

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)

Fusible link Fuse ABS actuator and electric unit To motor relay

Solenoid valve relay

(Malfunction code Nos. 41, 42, 45, 46, 51, 52, 55, 56, 63 for models with self-diagnosis function) CHECK FUSIBLE LINK. Check 40A fusible link g (petrol engine), fusible link h (diesel engine). For fusible link layout, refer to POWER SUPPLY ROUTING in EL section. H

H ABS actuator and electric unit connector : With petrol engine : With diesel engine

YBR174

NG

p

(Go to next page.)

E B

No

E

Inspection end

Yes

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT. Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75.

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

(Go to next page.)

OK

CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? H

p

E A

OK

CHECK FUSE. Check 10A fuse 19 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section.

ABS control unit

NG

NG

E

Repair harness and connector.

E

Check the following. ● Harness connector

OK YBR175

H

CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 (body side) terminal p 29 and ground. Battery voltage should exist. H

OK

REPLACE. Replace ABS actuator and electric unit.

BR-79

NG

E78

Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness or connector.

●

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay) (Cont’d) A p

H

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

REPLACE. Replace fusible link. Does the fusible link blow out when ignition switch is turned ON?

No

E

Inspection end

Yes YBR176

H

CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT. 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 29 and ground. Continuity should not exist. H

NG

E

Check the following ● Harness connector E78

Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness or connector.

●

OK

REPLACE. Replace ABS actuator and electric unit.

B p

H

REPLACE. Replace fuse. Does the fuse blow out when ignition switch is turned ON? No

H

END Inspection end

BR-80

Yes

E

Check the following. ● Harness connector E78

Harness for open or short between ABS actuator and electric unit and fuse If NG, repair harness or connector.

●

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 3 (Motor Relay or motor)

Fuse Fusible link

ABS actuator and electric unit

Motor relay

To solenoid valve relay

CHECK FUSIBLE LINK. Check 40A fusible link i (Petrol engine), fusible link f (diesel engine). For fusible link layout, refer to POWER SUPPLY ROUTING in EL section. H

ABS control unit

NG

p

E A

(Go to next page.)

OK

CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?

ABS actuator and electric unit connector : With petrol engine : With diesel engine

(Malfunction code No. 61 for models with self-diagnosis function)

No

E

Inspection end

Yes YBR177

H

CHECK MOTOR RELAY POWER SUP- NG PLY CIRCUIT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 (body side) terminal p 30 and ground. Battery voltage should exist.

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

H YBR178

OK

REPLACE. Replace ABS actuator and electric unit.

BR-81

NG

Check the following. ● Harness connector E78

Harness for open or short between ABS actuator and electric unit and fusible link. If NG, repair harness or connector.

●

OK

CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND. Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75. H

E

E

Repair harness and terminals.

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS Diagnostic Procedure 3 (Motor Relay or motor) (Cont’d) A p

ABS ACTUATOR AND ELECTRIC UNIT AND CONNECTOR

H

REPLACE. Replace fusible link. Does the fusible link blow out when ignition switch is turned ON?

No

E

Inspection end

OK YBR179 H

CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT. 1. Disconnect battery cable and ABS actuator and electric unit connector E78 . 2. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 30 and ground. Continuity should not exist. OK H

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

BR-82

NG

E

Check the following ● Harness connector E78

Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector.

●

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS .

Diagnostic Procedure 4 (Low voltage)

Fuse

(Malfunction code No. 57 for models with self-diagnosis function)

ABS actuator and electric unit To solenoid valve relay

CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?

ABS control unit

YBR180 H

YBR181

E

Inspection end

Yes CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E78 terminal p 1 and ground. Battery voltage should exist when ignition switch is turned ON.

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

No

H

A p

E

(See below.)

OK

CHECK ABS CONTROL UNIT GROUND Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-75. H

NG

NG E

Repair harness and connector.

OK

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

A p

H

CHECK FUSE. Check 10A fuse 19 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section. H

OK

Check battery. Refer to BATTERY in EL section.

BR-83

E

Replace fuse.

OK

CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT Check continuity between fuse and ABS actuator and electric unit connector E78 (body side) terminal p 1 . H

NG

NG E

Check the following: ● Harness connector E78 ● Harness for open or short between ABS actuator and electric unit and fuse If NG, repair harness or connector.

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS .

Diagnostic Procedure 5 (Control unit)

Fuse

(Malfunctioning code No. 71 for models with self-diagnosis function) ABS actuator and electric unit

CHECK CONNECTOR. 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again?

ABS control unit

No E

Inspection end

YBR182 H

Yes

ABS CONTROL UNIT POWER SUPPLY CHECK Check voltage. Refer to in Diagnostic Procedure 4, BR-83. H

CHECK SELF-DIAGNOSTIC RESULTS Does warning lamp indicate code No. 71 again? H

No

INSPECTION Inspect the system according to the code No.

BR-84

Yes E

Replace ABS actuator and electric unit.

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 6 (ABS works frequently) CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check. Refer to Diagnostic Procedure 1, BR-77. H

Go to BR-86.

OK

in Diagnostic Procedure 8,

BR-85

E

Perform Preliminary check. Refer to BR-59.

OK

CHECK FRONT AXLES Check front axles for excessive looseness. Refer to FA and RA section (“Front/Rear Wheel Bearing”, “ON-VEHICLE SERVICE”). H

NG

NG E

Repair.

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 7 (Unexpected pedal action) CHECK BRAKE PEDAL STROKE. Check brake pedal stroke. Is stroke excessively large? H SBR540A

Yes

E

Perform Preliminary Check, refer to BR-59.

E

Perform Preliminary Check, refer to BR-59.

E

Carry out self-diagnosis. Refer to BR-67.

E

Repair.

No

CHECK BRAKE PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether brake is effective.

No

Yes H

CHECK WARNING LAMP ACTIVATE. Ensure warning lamp remains off while driving.

NG

OK H ABS warning light NBR284

CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check. Refer to Diagnostic Procedure 1, BR-77.

NG

OK H

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals fir damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

Diagnostic Procedure 8 (Long stopping distance) CHECK ABS PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether stopping distance is still long.

No

E

in Diagnostic Go to Procedure 7, BR-86.

Yes H

Perform Preliminary Check and air bleeding.

Note: Stopping distance may be larger than vehicles without ABS when road condition is slippery.

BR-86

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 9 (ABS does not work.) CHECK WARNING LAMP ACTIVATE. Does the ABS warning lamp activate?

Yes

E

Carry out self-diagnosis. Refer to BR-67.

No H

Go to BR-86.

in Diagnostic Procedure 7,

Note: ABS does not work when vehicle speed is under 10 km/h (6 MPH).

Diagnostic Procedure 10 (Pedal vibration and noise)

Brake pedal

INSPECTION START 1. Apply brake. 2. Start engine. 3. Does the symptom appear only when engine is started?

Yes

E

Carry out self-diagnosis. Refer to BR-67.

E

Go to in Diagnostic Procedure 7, BR-86.

E

Repair wheel sensor.

No SAT797A

H

CHECK IF SYMPTOM APPEARS. Does the symptom appear when electrical equipment switches (such as headlamp) are operated?

No

Yes H

CHECK WHEEL SENSOR. Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and “HARNESS LAYOUT” in EL section.

NG

OK H

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

Note: ABS may operate and cause vibration under any of the following conditions.

BR-87

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 10 (Pedal vibration and noise) (Cont’d) ● ● ● ● ●

Applying brake gradually when shifting or operating clutch. Low friction (slippery) road. High speed concerning. Driving over bumps and pot holes. Engine speed is over 5,000 rpm with vehicle stopped.

Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON)

.

Fuse Combination meter ABS warning lamp

CHECK FUSE. Check 10A fuse 12 . For fuse layout, refer to POWER SUPPLY ROUTING in EL section.

ABS actuator and electric unit

NBR415

No

H

CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT. 1. Install 10A fuse. 2. Disconnect ABS actuator and electric unit connector. 3. Check voltage between control unit connector terminal 21, 22 and ground after turning ignition switch “ON”.

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

H

CVT models M/T models

E

Replace fuse.

OK

ABS control unit CVT models M/T models

NG

B p

NBR416

BR-88

Yes (Go to next page.)

p

E A

(Go to next page.)

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 11 (ABS Warning lamp does not come on when ignition switch is turned ON) (Cont’d) A p

H

ABS warning light NBR284

CHECK WARNING LAMP INDICATION. Disconnect ABS actuator and electric unit connector. Does the warning lamp activate?

NG

p

E B

(See below)

Yes H

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest

NG

E

REPLACE. Replace ABS actuator and electric unit.

OK H

Inspection end.

B p

H

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

.

21: CVT models 22: M/T models NBR417

CHECK HARNESS FOR SHORT. 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector (body side) terminal 21, 22, and ground. Battery voltage should not exist. OK H

CHECK COMBINATION METER. Check combination meter. Refer to WARNING LAMPS in EL section.

BR-89

NG

E

Repair harness or connector between fuse and ABS actuator and electric unit connector terminal.

TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 12 (Warning lamp stays on when ignition switch is turned ON)

.

Fuse Combination meter ABS warning lamp

ABS actuator and electric unit ABS control unit CVT models M/T models

NBR418

CHECK WARNING LAMP. 1. Disconnect ABS actuator and electric unit connector. 2. Connect suitable wire between ABS actuator and electric unit connector E78 (body side) terminal p 6 , p 22 and ground. Warning lamp should not activate.

NG

E

E78

Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector

●

OK

H

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

CVT models M/T models

NBR419

CHECK HARNESS CONNECTOR. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

Repair combination meter. Check the following ● Harness connector

OK

E

Inspection end.

NG H

ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR

YBR186

CHECK ABS MOTOR GROUND. 1. Turn ignition switch OFF. 2. Disconnect ABS actuator and electric unit connector. 3. Check continuity between ABS actuator and electric unit connector E78 (body side) terminal p 31 and ground. Continuity should exist. OK H

REPLACE. Replace ABS actuator and electric unit.

BR-90

NG

E

Check the following ● Harness connector E78

Harness for open or short between ABS actuator and electric unit and fusible link If NG, repair harness ro connector

●

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Unit: mm (in)

Applied model

QG16DE, QG18DE and CD20T

QG16DE, QG18DE and CD20T

For LHD models (except Wagon)

For RHD models & Wagon models (LHD/RHD)

Without ABS

With ABS (optional for LHD models)

Front brake Brake model

SR20DE CVT models

M/T models

With ABS

CL25VG

CL25VBG

FN3-57/22

disc brake

disc brake

disc brake

Cylinder bore diameter

57.2 (2.252)

Pad length × width × thickness

109 x 50.1 x 11 (94.29 x 1.97 x 0.43)

109 x 50.1 x 11 (4.29 x 1.97 x 0.43)

257 × 22 (10.12 × 0.87)

Rotor outer diameter × thickness Rear brake Brake model Cylinder bore diameter Lining or pad length × width × thickness Drum inner diameter or rotor outer Diameter × thickness

280 × 22 (11.04 × 0.87)

CL9HCG

LT20N

CL9HDG

CL11HEG

disc brake

drum brake

disc brake

disc brake

34.4 (1.354)

17.46 (0.6874)

34.4 (1.354)

38.2 (1.504)

79.8 x 38.5 x 9.3 (3.14 x 1.52 x 0.37)

195 x 35 x 4.5 (7.68 x 1.38 x 0.18)

258 x 10 (10.2 x 0.39)

203.2 (8.00)

Master cylinder Cylinder bore diameter

79.8 x 38.5 x 9.3 (3.14 x 1.52 x 0.37) 278 x 10 (10.9 × 0.39)

258 x 10 (10.2 x 0.39)

23.81 (0.94)

Control valve Valve model

Dual proportioning valve

—

1.96 (0.0196, 0.0200, 0.284) x 0.4

—

2

Split point [kPa (bar, kg/cm , psi)] × reducing ratio

112 x 56.2 x 11 (4.41 x 2.21 x 0.43)

Brake booster Booster model

BJKCE

Diaphragm diameter

Primary: 205 (8.1) Secondary: 180 (7.1)

Specified brake fluid

DOT 4

BR-91

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment DISC BRAKE Unit: mm (in) CL25VG

CL25VBG

FN3-57/22

CL9HCG

CL9HDG

CL11HEG

Pad wear limit Minimum thickness Rotor repair limit Minimum thickness

2.0 (0.079) 20.0

20.0

20.0

9.0

9.0

9.0

(0.787)

(0.787)

(0.787)

(0.354)

(0.354)

(0.354)

Maximum runout

0.07 (0.0028)

Maximum thickness variation

0.02 (0.0008)

DRUM BRAKE Unit: mm (in) Brake model Lining wear limit

LT20N Minimum thickness

1.5 (0.059)

Maximum inner diameter

204.5 (8.051)

Maximum out-of-round

0.03 (0.0012)

Drum repair limit

BRAKE PEDAL Unit: mm (in) Applied model

RHD

LHD

M/T

160 - 170 (6.30 - 6.69)

151 - 161 (5.94 - 6.34)

CVT

169 - 179 (6.65 - 7.05)

160 - 170 (6.30 - 6.69)

M/T

80 - 90 (3.15 - 3.54)

71 - 81 (2.80 - 3.19)

CVT

89 - 99 (3.50 - 3.90)

80 - 91 (3.15 - 3.54)

Free height

Depressed height [under force of 490 N (50 kg, 110 lb) with engine running]

PARKING BRAKE CONTROL Control type

Center lever

Number of notches [under force of 196 N (20 kg, 44 lb)] Number of notches when warning switch comes on

6-8 1

BR-92

STEERING SYSTEM SECTION

ST

CONTENTS PRECAUTIONS AND PREPARATION.......................... 2 Precautions ................................................................ 2 Preparation ................................................................ 2 PREPARATION.............................................................. 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................... 4 NVH Troubleshooting Chart....................................... 4 ON-VEHICLE INSPECTION .......................................... 5 Checking Steering Wheel Play.................................. 5 Checking Neutral Position on Steering Wheel .......... 5 Front Wheel Turning Angle........................................ 5 Checking Gear Housing Movement .......................... 5 Checking and Adjusting Drive Belts .......................... 6 Checking Fluid Level ................................................. 6 Checking Fluid Leakage ............................................ 6 Bleeding Hydraulic System........................................ 6 Checking Steering Wheel Turning Force .................. 7 Checking Hydraulic System....................................... 8 STEERING WHEEL AND STEERING COLUMN.......... 9 Removal and Installation ......................................... 10 Disassembly and Assembly......................................11 Inspection................................................................. 12

POWER STEERING GEAR AND LINKAGE .............. 14 Removal and Installation ......................................... 14 Disassembly............................................................. 17 Inspection................................................................. 17 Assembly ................................................................. 19

SR20DE POWER STEERING OIL PUMP.................................. 20

CD20T POWER STEERING OIL PUMP.................................. 21

QG16, 18DE POWER STEERING OIL PUMP.................................. 22

SR20DE, CD20T, QG16DE, QG18DE SERVICE DATA AND SPECIFICATIONS (SDS) ........ 23 General Specifications............................................. 23 Inspection and Adjustment ...................................... 23

ST

PRECAUTIONS AND PREPARATION Precautions Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death (in the event of a collision which would result in air bag inflation), all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness), for easy identification.

STEERING SYSTEM ● ● ● ● ● ● ●

Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order on a part rack so they can be reinstalled in their correct positions. Only use nylon cloths or paper towels to clean parts. Do not use rags or other materials containing lint. Residual debris may damage the system. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied to O-rings and seals. Do not use any grease. Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installation. Perform functional tests whenever designated. *: Automatic transmission fluid

Preparation SPECIAL SERVICE TOOL Tool number Tool name

Description

ST27180001 Steering wheel puller

Removing and installing steering wheel

NT170

ST-2

PREPARATION SPECIAL SERVICE TOOLS Tool number Tool name

Description

KV48100700 Torque adapter

Measuring pinion rotating torque

HT72520000 Ball joint remover

Removing ball joint

ST27091000 Pressure gauge

Measuring oil pressure

KV48102500 Pressure gauge adapter

Measuring oil pressure

ST3127S000 1 GG91030000 p Torque wrench 2 HT62940000 p Socket adapter 3 HT62900000 p Socket adapter

Measuring turning torque

ST-3

Symptom STEERING ST-18 ST-19 ST-6 ST-5 ST-7

Tie-rod ball joint rotating torque Tie-rod ball joint end play Steering gear fluid leakage Steering wheel play Steering wheel turning force Drive belt looseness

X X X X X X X X

Judder

X: Applicable

ST-4 X

X X X X X

X X X X X X

X X

ST-5 ST-13 ST-11 ST-14

Mounting rubber deterioration Steering column deformation or damage Improper installation or looseness of steering column Steering linkage looseness

NVH in BR section

X

X

BRAKES

X

X

NCH in FA section

X

X

ROAD WHEEL

X

Shimmy

NVH in FA section

Vibration TIRES

X

NVH in FA, RA section

X

AXLE AND SUSPENSION

X

NVH in FA section

Shake DRIVE SHAFT

ST-12

— Improper installation or looseness of tilt lock lever

Improper steering wheel

ST-18

Tie-rod ball joint swinging force

X

Refer to MA section.

ST-6

Noise Air in hydraulic system

Possible cause and SUSPECTED PARTS ST-6

Reference page

Fluid level

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X X X X X

X X X X X

X

ON-VEHICLE INSPECTION Checking Steering Wheel Play 1. With wheels in a straight-ahead position, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less 2. If it is not within specification, check steering gear assembly when front suspension and axle, steering gear assembly and steering column are mounted correctly. .

SST489B

Checking Neutral Position on Steering Wheel Pre-checking ●

●

Make sure that wheel alignment is correct. Wheel alignment: Refer to SDS in FA section Verify that the steering gear is centered before removing the steering wheel.

Checking SST490BA

1. Check that the steering wheel is in the neutral position when driving straight ahead. 2. If it is not in the neutral position, remove the steering wheel and reinstall it correctly. 3. If the neutral position is between two serrated teeth, loosen tie-rod lock nut and move tie-rod in the opposite direction by the same amount on both left and right sides to compensate for error in the neutral position.

Front Wheel Turning Angle 1. Rotate steering wheel all the way right and left; measure turning angle. Turning angle of full turns: Refer to SDS in FA section 2. If it is not within specification, check rack stroke. Rack stroke “S”: Refer to SDS (ST-23) SMA127

Checking Gear Housing Movement

.

SST059B

1. Check the movement of steering gear housing during stationary steering on a dry paved surface. ● Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check the gear housing movement. Turn off ignition key while checking. Movement of gear housing: ±2 mm (±0.08 in) or less 2. If movement exceeds the limit, replace mount insulator after confirming correct installation of gear housing clamps.

ST-5

ON-VEHICLE INSPECTION Checking and Adjusting Drive Belts Refer to section MA for Drive Belt Inspection.

Checking Fluid Level COLD: 0 - 30°C (32 - 86°F)

HOT: 50 - 80°C (122 - 176°F)

Check fluid level. Fluid level should be checked using “HOT” range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) or using “COLD” range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: ● Do not overfill. ● Recommended fluid is Automatic Transmission Fluid “DEXRONTM” type.

NST031

Checking Fluid Leakage

SST681B

Check the lines for security, leaks, cracks, damage, loose connections, chafing or deterioration. 1. Run engine between idle speed and 1,000 rpm. Make sure temperature of fluid in oil tank rises to 60 to 80°C (140 to 176°F). 2. Turn steering wheel right-to-left several times. 3. Hold steering wheel at each “lock” position for five seconds and carefully check for fluid leakage. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. 5. Check rack boots for accumulation of power steering fluid.

Bleeding Hydraulic System 1. Raise front end of vehicle until wheels are clear of the ground. 2. Add fluid into oil tank to specified level. Then quickly turn steering wheel fully to right and left and lightly touch steering stoppers. Repeat steering wheel operation until fluid level no longer decreases. 3. Start engine. Repeat step 2 above.

ST-6

ON-VEHICLE INSPECTION Bleeding Hydraulic System (Cont’d) Incomplete air bleeding will cause the following to occur. When this happens, bleed air again. a. Generation of air bubbles in reservoir tank b. Generation of clicking noise in oil pump c. Excessive buzzing in oil pump While the vehicle is stationary or while moving the steering wheel slowly, fluid noise may occur in the valve or oil pump. This noise is inherent in this steering system, and it will not affect performance or durability of the system. ●

Checking Steering Wheel Turning Force

SST491B

SST090B

1. Park vehicle on a level, dry surface and set parking brake. 2. Start engine. 3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is approximately 60 to 80°C (140 to 176°F).] Tires need to be inflated to normal pressure. 4. Check steering wheel turning force when steering wheel has been turned 360° from neutral position. Steering wheel turning force: 44.1 N (4.5 kg, 9.9 lb) or less

5. If steering wheel turning force is out of specification, check rack sliding force to detect condition of steering gear assembly. a. Disconnect steering column lower joint and knuckle arms from the gear. b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature. c. While pulling tie-rod slowly from the neutral position, make sure rack sliding force is within specification. Rack sliding force: 284 N (29 kg, 64 lb) or less 6. If rack sliding force is not within specification, replace steering gear assembly.

ST-7

ON-VEHICLE INSPECTION Checking Hydraulic System

ST27091000

Highpressure hose Pump

Gear

Tank Direction of oil flow

Low-pressure hose

SST834

Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. (See “Bleeding Hydraulic System”.) 2. Run engine. Make sure temperature of fluid in tank rises to 60 to 80°C (140 to 176°F). WARNING: Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, oil pressure in oil pump will increase to relief pressure, resulting in an abnormal rise in oil temperature. 3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Oil pump maximum standard pressure: QG: 7,502 - 8,101 kpa (75 - 81 bar, 76.5 - 82.6 kg/cm2, 1,088 - 1,175 psi) SR: 7,002 - 7,600 kPa (70 - 76 bar, 71.4 - 77.5 kg/cm2, 1,015 - 1,102 psi) CD: 7,690 - 8,493 kpa (77 - 85 bar, 78,5 - 86,6 kg/cm2, 1,116 - 1,231 psi) 4. If oil pressure is below the standard pressure, slowly close shut-off valve and check pressure. ● When pressure reaches above standard pressure, gear is damaged. ● When pressure remains below standard pressure, pump is damaged. CAUTION: Do not close shut-off valve for more than 15 seconds. 5. After checking hydraulic system, remove Tool and add fluid as necessary, then completely bleed air out of system.

ST-8

STEERING WHEEL AND STEERING COLUMN

SEC. 484⋅487⋅488

Spiral cable

Upper column cover

29 - 39 (3.0 - 4.0, 22 - 29)

Horn pad (Including Airbag module)

Steering column assembly

Ignition switch grommet

13 - 18 (1.3 - 1.8, 9 - 13)

Steering wheel

Lower column cover

15 - 19 (1.5 - 1.9, 11 - 14) : N·m (kg-m, ft-lb)

Push-on nut

NST019

CAUTION: ● The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. ● Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.

ST-9

STEERING WHEEL AND STEERING COLUMN Removal and Installation STEERING WHEEL ●

●

Remove screws from both sides of steering wheel and pull out horn pad. Refer to RS section for Air Bag Module and Spiral Cable Removal. Align spiral cable correctly when installing steering wheel. Refer to RS-section.

NBF004

STEERING COLUMN ●

●

When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. When attaching coupling joint, be sure tightening bolt faces cutout portion.

NST003

●

Align slit of lower joint with projection on dust cover. Insert joint until surface A contacts surface B.

CAUTION: After installing steering column, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driving straight ahead. Steering gear SST491C

ST-10

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly SEC. 488

Combination switch assembly

Spiral cable assy

Snap ring Washer O-ring

Jacket tube assembly

Boot

24 - 29 (2.4 - 3.0, 17 - 22)

24 - 29 (2.4 - 3.0, 17 - 22) Column shaft assembly : N·m (kg-m, ft-lb) : Do not re-use

Lower joint

NST020

WARNING: Refer to ‘PRECAUTIONS” (on page ST-2) and to RS section for spiral cable servicing information.

● Screws remain captive in switch

Remove

To remove combination switch, remove attaching screws, disconnect harnesses and remove switch.

NST021

ST-11

STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly (Cont’d) ● ●

Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring on upper shaft with a suitable tool.

SST770A

● Steering lock a. Break self-shear type screws with a drill or other appropriate tool.

SST741A

b. Install self-shear type screws and then cut off self-shear type screw heads.

SST742A

Inspection Tilt mechanism ● After installing steering column, check tilt mechanism operation.

SST582B

ST-12

STEERING WHEEL AND STEERING COLUMN Inspection (Cont’d) When steering wheel does not turn smoothly, check the steering column as follows and replace damaged parts. a. Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. b. Check jacket tube for deformation or breakage. Replace if necessary. ● When the vehicle is involved in a light collision, check column length “L”. If it is not within specifications, replace steering column as an assembly. Column length “L”: 536.0 - 538.0 mm (21.10 - 21.18 in) ●

SST583B

ST-13

POWER STEERING GEAR AND LINKAGE Removal and Installation SEC. 492

: Do not re-use SST584B

●

Detach tie-rod outer sockets from knuckle arms with Tool.

CAUTION: ● The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. ● Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.

HT72520000

SFA372

● ●

Remove low and high pressure connectors Remove exhaust front tube.

SST574B

ST-14

1 p

and

2 . p

POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) ●

Remove dust cover from steering lower joint. Remove joint.

●

Remove harness from subframe mounting bracket.

●

Remove gear housing brackets.

●

Support transmission housing with engine jack. Remove center member with engine mounting rear bracket.

SST578B

UST003

SST577B

●

SST579B

●

.

Guide transfer tube over harness mounting bracket. Slide gear to left side of vehicle, lower and remove from right side as illustrated.

SST581B

ST-15

POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) ● ●

●

SST574B

●

●

Install pipe connector. Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive tightening can damage threads or damage connector O- ring. The O-ring in low-pressure pipe connector is larger than that in high-pressure connector. Take care to install the correct O-ring. Connector tightening torque: Low-pressure side “p 1 ” 20 - 25 N·m (2.0 - 2.6 kg-m, 14 - 19 ft-lb) High-pressure side “p 2 ” 15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb) Ensure that steering gear is correctly aligned in housing brackets, and that transfer tubes do not foul bulkhead or subframe.

Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed.

CAUTION: Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).

SST824A

ST-16

POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) SEC. 492

SST585B

Disassembly Always use soft jaws when clamping steering gear housing in a vise. Handle gear housing carefully, as it is made of aluminum. 1. Remove outer tie-rod. 2. Remove dust boot. .

Jaw protectors

NST022

Inspection Thoroughly clean all parts in cleaning solvent or automatic transmission fluid “DexronTM” type, and blow dry with compressed air, if available.

ST-17

POWER STEERING GEAR AND LINKAGE Inspection (Cont’d) STEERING GEAR ASSEMBLY ● ● ●

Check for smooth operation through a full stroke. Check rack and tie-rod for cracks, deformation or other damage. Check pinion rotating torque. Pinion rotating torque: 0.8 - 1.3 N·m (8 - 13 kg-cm, 6.9 - 11.3 in-lb)

SST587B

●

Check rack sliding force. Rack sliding force: 284 N (29 kg, 64 lb) or less

SST090B

BOOT Check condition of boot. If cracked, replace it.

TIE-ROD OUTER AND INNER SOCKET ●

Check ball joint for swinging force. A Tie-rod outer ball joint: 3.3 - 67 N (0.34 - 6.8 kg, 0.74 - 15.1 lb) B Tie-rod inner ball joint: 0.3 - 24.5 N (0.03 - 2.5 kg, 0.07 - 5.5 lb)

●

Check ball joint for rotating torque. Tie-rod outer ball joint: 0.15 - 2.9 N·m (1.5 - 30 kg-cm, 1.3 - 26.0 in-lb)

Measuring point

SST588B

ST3127S000

SST751A

ST-18

POWER STEERING GEAR AND LINKAGE Inspection (Cont’d) ●

●

Check ball joint for axial end play. Tie-rod outer ball joint: 0 mm (0 in) Tie-rod inner ball joint: 0 mm (0 in) Check condition of dust cover. If cracked excessively, replace it.

SST334B

Assembly 1. Measure rack stroke. Rack stroke “S”: Refer to SDS (ST-23)

NST023

2. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.

SST589B

3. Tighten outer socket lock nut. Tie-rod length “L”: Refer to SDS (ST-24)

SST093B

ST-19

POWER STEERING OIL PUMP

Adjuster bolt

SR20DE

Bracket 49 - 68 (5.0 - 6.9, 37 - 50)

13.4 - 18 (1.4 - 1.8, 10 - 13)

: N·m (kg-m, ft-lb) : Do not re-use NST043

ST-20

POWER STEERING OIL PUMP

Adjuster bolt

CD20T

Bracket

38 - 49 (3.9 - 4.9, 28 - 36)

49 - 68 (5.0 - 6.9, 28 - 36)

: N·m (kg-m, ft-lb) : Do not re-use NST044

ST-21

QG16, 18DE

POWER STEERING OIL PUMP

Align so that white mark on hose aligns with mark on suction port Adjuster bolt

CLIP TO FACE REARWARDS 49 - 68 (5.0 - 6.9, 28 - 36)

Bracket

Switch

Hose

: N·m (kg-m, ft-lb) : Do not re-use NST045

ST-22

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications Applied model 15″ tire Steering model

16″ tire

Power steering

Steering gear type

PR25T

Steering overall gear ratio Turn of steering wheel (Lock to lock)

16.7 2.7

Steering column type

2.6

Tilt / collapsible

Inspection and Adjustment STEERING WHEEL AND COLUMN Applied model

STEERING GEAR

Tilt

Power PR25T Steering gear type

Steering wheel axial play mm (in)

0 (0) Rack stroke “S”

Steering wheel play

35 (1.38) or less

mm (in) Steering column length “L” mm (in)

mm (in)

Pinion rotating torque N·m (kg-cm, in-lb)

536 - 538 (21.10 - 21.18 in)

Rack sliding force N (kg, lb)

L

15” tire

16” tire

68 (2.68)

66 (2.60)

0.8 - 1.3 (8 - 13, 6.9 - 11.3) 284 (29, 64) or less

Steering wheel turning force (Measured at one full turn from neutral) N (kg, lb)

44.1 (4.5, 9.9) or less

Fluid capacity (Approximate)  (Imp qt)

0.9 (3/4)

Oil pump relief pressure kPa (bar, kg/cm2, psi)

SR: 7,002 - 7,600, (70 - 76, 71.4 - 77.5, 1,109 - 1,194) QG: 7,502 - 8,101, (75 - 81, 76.5 - 82,6) CD: 7,748 - 8,532 (77.5 - 85.3, 79 - 87, 1,123 - 1,237)

SST583B

NST023

ST-23

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont’d) STEERING LINKAGE Power PR25T

Steering gear type Movement of gear housing mm (in)

±2 (±0.08) or less

Tie-rod outer ball joint A

Swinging force at cotter pin hole N (kg, lb)

3.3 - 67 (0.34 - 6.8, 0.74 - 15.1)

Rotating torque N·m (kg-cm, in-lb)

0.15 - 2.4 (1.5 - 30, 1.3 - 26.0)

Axial end play mm (in)

0 (0)

Tie-rod inner ball joint B

Swinging force* N (kg, lb)

0.3 - 24.5 (0.03 - 2.5, 0.07 - 5.5)

Axial end play mm (in)

0 (0)

Tie-rod standard length “L” mm (in)

183.6 (7.23)

*Measuring point

SST588B

SST093B

ST-24

RESTRAINT SYSTEM SECTION

RS

CONTENTS PRECAUTION................................................................ 2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 2 SEAT BELT.................................................................... 3 Front Seat Belt........................................................... 3 Rear Seat Belt (4-door models) ................................ 4 Rear Seat Belt (Wagon and 5-door models)............. 6 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).......... 8 Precautions for SRS ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ Service............................. 8 Special Service Tools ................................................ 8 Description ............................................................... 10 SRS Component Parts Location ..............................11 Maintenance Items .................................................. 12 Removal and Installation - Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor...................................................................... 13 Removal - Air Bag Module and Spiral Cable .......... 14 Installation - Air Bag Module and Spiral Cable ....... 16

Removal - Front Passenger’s Air Bag Module........ 17 Installation - Front Passenger’s Air Bag Module..... 18 Removal - Side Air Bag Module .............................. 19 Installation - Side Air Bag Module ........................... 20 Disposal of Air Bag Module and Seat Belt Pretensioner .................................................................. 22 TROUBLE DIAGNOSES - SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ...................................... 28 Trouble Diagnoses Introduction............................... 28 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 30 Schematic ................................................................ 32 Wiring Diagram - SRS -........................................... 33 SRS-Operation Check ............................................. 37 Trouble Diagnoses with CONSULT-II................. 38 Trouble Diagnoses without CONSULT-II............ 48 Trouble Diagnoses for Air Bag Warning Lamp........ 56 COLLISION DIAGNOSIS............................................. 57

When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. ● See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. ● See EL section for NATS information and wiring diagram. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

RS

PRECAUTION Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to the destination and optional equipment): ● For a frontal collision The Supplemental Restraint System consists of driver’s air bag module (located in the center of the steering wheel), front passenger’s air bag module (located on the instrument panel on passenger’s side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and SRS wiring harnesses except “SEAT BELT PRE-TENSIONER” connectors can be identified by yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). CAUTION: ● Before removing the seat belt pre-tensioner assembly, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use electrical test equipment for seat belt pre-tensioner connector. ● After replacing or installing seat belt pre-tensioner assembly, or reconnecting seat belt pre-tensioner connector, check the system function. Refer to “SRS Operation Check” (RS-37) for details. ● Do not disassemble buckle or seat belt assembly. ● Replace anchor bolts if they are deformed or worn out. ● Never oil tongue and buckle. ● If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt assembly. ● If webbing is cut, frayed, or damaged, replace seat belt assembly. ● When replacing seat belt assembly, use a genuine seat belt assembly. ● After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (i.e., guide rail set).

RS-2

SEAT BELT Front Seat Belt 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p

Slide the seat all the way forward. Remove center pillar lower garnish. Refer to “INTERIOR TRIM” in BT section for details. Disconnect seat belt pre-tensioner subharness connector from the main harness. Remove the cover of the shoulder adjustment. Remove the seat belt from the shoulder adjuster. Remove center pillar upper garnish. Refer to “INTERIOR TRIM” in BT section for details. Remove bolts securing sash guide, then remove sash guide. Remove the seat belt pre-tensioner retractor anchor bolt. Remove the bolt securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor. Remove shoulder adjustment, taking care not to damage plastic garnish. 43 - 55 (4.4 - 5.6, 32 - 41)

Adjuster cover

43 - 55 (4.4 - 5.6, 32 - 41)

.

Washer

5.1 - 6.3 (0.52 - 0.64, 45 - 56) .

5.1 - 6.3 (0.52 - 0.64, 45 - 56)

Bush Washer Washer Anchor bolt

Bush Washer

.

: N·m (kg-m, ft-lb) Washer 43 - 55 (4.4 - 5.6, 32 - 41)

: N·m (kg-m, in-lb) .

Anchor bolt

RS-3

43 - 55 (4.4 - 5.6, 32 - 41)

: Do not re-use NRS054

SEAT BELT Rear Seat Belt (4-door models) MODELS WITH 2-POINT CENTER SEAT BELT 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p

Remove rear seat cushion. Refer to “SEAT” in BT-section for details. Remove each anchor bolt. Remove both sides of the back of the seat. Fold down rear seat. Remove high mounted stop lamp from parcel shelf (where fitted). Remove rear pillar garnish. Remove the parcel shelf. Remove the bolt and screw which secure the rear seat belt retractors.

.

20.6 - 26.5 (2.1 - 2.7, 16 - 19)

Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41) 20.6 - 26.5 (2.1 - 2.7, 16 - 19)

2.0 - 3.0 (0.2 - 0.31, 1 - 2) 43 - 55 (4.4 - 5.6, 32 - 41)

.

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) NRS055

RS-4

SEAT BELT Rear Seat Belt (4-door models) (Cont’d) MODELS WITH 3-POINT CENTER SEAT BELT: For outboard seat belts refer to “models with 2 point center seat belt”. 1 Remove rear seat cushion. Refer to “SEAT” in BT section for details. p 2 Remove anchor bolts. p 3 Fold down LH-side backrest. p 4 Remove finisher located behind the armrest (where fitted). p 5 Remove trim on the rearside of the backrest. p 6 Remove finisher. p 7 Remove anchor bolt. p 8 Pull the retractor out of the backrest. p

.

.

20.6 - 26.5 (2.1 - 2.7, 16 - 19)

43 - 55 (4.4 - 5.6, 32 - 41)

Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41)

20.6 - 26.5 (2.1 - 2.7, 16 - 19)

B Tightening sequence A: finger tight B: 43 - 55 (4.4 - 5.6, 32 - 41) C: 43 - 55 (4.4 - 5.6, 32 - 41)

43 - 55 (4.4 - 5.6, 32 - 41)

A, C

N·m (kg-m, ft-lb)

RS-5

NRS056

SEAT BELT Rear Seat Belt (Wagon and 5-door models) MODELS WITH 2-POINT CENTER SEAT BELT 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p

Remove rear seat cushion. Refer to “SEAT” in BT-section for details. Remove each anchor bolt. Fold down rear seat back. Remove rear seat back carpet and clips. Remove seat belt retractor escutcheon. Unclip rear seat back lock release button then remove the lock release escutcheon. Remove fabric covering portion of the seat belt retractor. Remove the seat belt retractor cover. Loosen the seat belt retractor anchor bolt, then remove the seat belt retractor. Remove interlock cable end from the seat belt retractor. (If necessary)

MODELS WITH 3-POINT CENTER SEAT BELT The procedure is same as 2-point center seat belt models. 6 should be skipped. When removing 3-point center seatbelt, the procedure p

RS-6

SEAT BELT Rear Seat Belt (Wagon and 5-door models) (Cont’d)

.

.

Child seat anchorage 43 - 55 (4.4 - 5.6, 32 - 41) . 20.6 - 26.5 20.6 - 26.5 (2.1 - 2.7, (2.1 - 2.7, 16 - 19) 16 - 19)

Clip

.

Rear seat back Suitable tool

43 - 55 (4.4 - 5.6, 32 - 41) Clip Seat belt retractor

Seat belt retractor

Pawl

RS-7

Pawl

NRS057

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service ● ●

●

● ●

● ●

Do not use electrical test equipment to check the SRS unless instructed to do in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “S” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to turn steering wheel or column after removal of steering gear. Handle air bag module carefully. Always place driver’s and passenger’s air bag modules with the pad side facing upward and place side air bag module (built-in type) standing with stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged.

Special Service Tools Tool number Tool name

Description

KV99106400 Deployment tool

Disposing of air bag module

NT357

KV99105300 Air bag module bracket

Anchoring air bag module

NRS016

HT61961000 and HT62152000 combined *Special torx bit

Use for special bolts [TAMPER RESISTANT TORX (Size T50)] a: 3.5 (0.138) dia. b: 8.5 - 8.6 (0.335 - 0.339) dia. c: approx. 10 (0.39) sq. Unit: mm (in)

NT361

Tamper resistant torx socket

Size: T30

NT757

*: Special tool or commercial equivalent

RS-8

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Special Service Tools (Cont’d) Tool number Tool name

Description

KV99108200 Deployment tool adapter for front seat belt pretensioner

For front seat belt pre-tensioner

NT796 -

KV99108300 Deployment tool adapters for Passenger and built-in type side air bag modules

For passenger airbag module and side airbag

NT744

*: Special tool or commercial equivalent

RS-9

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Description Driver’s air bag module

Seat belt pre-tensioner (Driver’s side)

Satellite sensor (LH) (G sensor for side air bag LH)

Passenger’s air bag module

Seat belt pre-tensioner (passenger’s side)

Diagnosis sensor unit

● ● ● ●

Auxiliary power source (condenser) Drive circuit CPU

Satellite sensor (RH) (G sensor for side air bag RH)

G sensor (for driver’s and passenger’s air bags, seat belt pre-tensioner)

● Safing sensor Side air bag module (LH) (Built-in type)

(for driver’s and passenger’s air bags, seat belt pre-tensioner)

Side air bag module (RH) (Built-in type)

● Safing sensor (for side air bag)

SRS585

The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in “ON” or “START” position. The collision modes for which supplemental restraint systems are activated are different among the SRS systems. For example, the driver’s air bag module and passenger’s air bag module are activated in a frontal collision but not in a side collision. SRS configurations which are activated for some collision modes are as follows; SRS configuration

Frontal collision

Left side collision

Right side collision

Driver’s air bag module

q

—

—

Passenger’s air bag module

q

—

—

Seat belt pre-tensioner (Driver’s side)

q

—

—

Seat belt pre-tensioner (Passenger’s side)

q

—

—

Side air bag module (LH)

—

q

—

Side air bag module (RH)

—

—

q

RS-10

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .

Built-in Type Side Air Bag

Front seat back with front side air bag (Built-in type)

Front side air bag is built-in type. The front seat back with built-in type side air bag has the labels as shown on the left figure.

NRS059

SRS Component Parts Location .

Passenger’s air bag module

Side air bag modules (Built-in type)

Driver’s air bag module Spiral cable

.

.

Diagnosis sensor unit

Seat belt pretensioner retractors Satellite sensors

Wiring harness

NRS125

RS-11

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Maintenance Items

SRS797-A

CAUTION: Do not use electrical test equipment to check SRS circuit. 1. Check operation of “AIR BAG” warning lamp. After turning ignition key to “ON” position, the “AIR BAG” warning lamp illuminates. The “AIR BAG” warning lamp will go off after about 7 seconds if no malfunction is detected. If any of the following warning lamp conditions occur, immediately check the air bag system. Refer to “SRS-Operation Check” for details. (RS-37) ● The “AIR BAG” warning lamp does not come on when the ignition switch is turned “ON”. ● The “AIR BAG” warning lamp does not go off about 7 seconds after the ignition switch is turned “ON”. ● The “AIR BAG” warning lamp blinks about 7 seconds after the ignition switch is turned “ON”. 2. Visually check SRS components. (1) Diagnosis sensor unit ● Check diagnosis sensor unit and bracket for dents, cracks or deformities. ● Check connectors for damage, and terminals for deformities. (2) Air bag module and steering wheel ● Remove air bag module from steering wheel, instrument panel or seat back. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. ● Install driver’s air bag module to steering wheel to check fit or alignment with the wheel. ● Check steering wheel for excessive free play. ● Install passenger’s air bag module to instrument panel to check fit or alignment with the instrument panel. ● Install side air bag module to seatback to check fit and alignment with the seat. (3) Spiral cable ● Check spiral cable for dents, cracks, or deformities. ● Check connectors and protective tape for damage. ● Check steering wheel for noise, binding or heavy operation. (4) Main harness, body harness and air bag harness ● Check connectors for poor connections, damage, and terminals for deformities. ● Check harnesses for binding, chafing or cuts. (5) Seat belt pre-tensioner ● Check harness cover and connectors for damage, terminals for deformities, and harness for binding. ● Check belts for damage and anchors for loose mounting. ● Check retractor for smooth operation. ● Perform self-diagnosis for seat belt pre-tensioner using “AIR BAG” warning lamp or CONSULT-II. Refer to “SRS Operation Check” for details. (RS-37) (6) Side airbag (Satellite) sensor ● Check Side airbag (Satellite) sensor (including bracket portion) for dents, cracks or deformities. ● Check connectors for damage, and terminals for deformities.

RS-12

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CAUTION: Replace previously used special bolts, ground bolt and nuts coated with bonding agent and also the anchor bolt with new ones.

Removal and Installation — Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. ● The special bolts are coated with bonding agent while the other bolt is for ground. Do not use old bolts after removal; replace with new ones. ● Check diagnosis sensor unit, seat belt pre-tensioner and satellite sensor for proper installation. ● Check diagnosis sensor unit and satellite sensor to ensure they are free of deformities, dents, cracks or rust. If it shows any visible signs of damage, replace them with new ones. ● Check diagnosis sensor unit brackets to ensure they are free of deformities and rust. ● After replacement of diagnosis sensor unit, seat belt pre-tensioner and satellite sensor check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check” for details. (RS-37) ● Do not attempt to disassemble diagosis sensor unit,seat belt pre-tensioner and satellite sensor ● Replace diagnosis sensor unit, seat belt pre-tensioner and satellite sensor if it has been dropped or sustained an impact. ● Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F).

REMOVAL OF DIAGNOSIS SENSOR UNIT

Diagnosis sensor unit .

Forward mark

Ground bolt

Special bolt 15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)

FRONT

NRS061

.

5.1 - 6.3 N·m (0.52 - 0.64 kg-m, 45 - 56 in-lb) .

.

Connector

Seat belt pre-tensioner

1. Disconnect driver’s, passenger’s- and side air bag module connectors. Also, disconnect seat belt pre-tensioner connector. 2. Remove lower instrument center panel. Refer to “INSTRUMENT PANEL” in BT section. 3. Disconnect diagnosis sensor unit connector. 4. Remove ground bolt and the special bolts by using the TAMPER RESISTANT TORX (Size T50), from diagnosis sensor unit. Then remove the diagnosis sensor unit. NOTE: ● To install, reverse the removal procedure sequence. ● Diagnosis sensor unit must always be installed with their arrow marks “S” pointing towards the front of the vehicle for proper installation.

REMOVAL OF SEAT BELT PRE-TENSIONER For removal of seat belt pre-tensioner, refer to “Front Seat Belt” for details. (RS-3) NOTE: ● To install, reverse the removal procedure sequence.

.

Anchor bolt 43 - 55 N·m (4.4 - 5.6 kg-m, 32 - 41 ft-lb)

NRS062

RS-13

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal and Installation — Diagnosis Sensor Unit, Seat Belt Pre-tensioner and Satellite Sensor (Cont’d) REMOVAL SATELLITE SENSOR Connector .

Ground bolt 2.94 - 4.9 (0.30 - 0.50, 26 - 43)

1. Remove seat belt pre-tensioner. Refer to “Front Seat Belt” for details. (RS-3) 2. Disconnect satellite sensor connector. 3. Remove bolt and nuts from satellite sensor unit. Then remove the satellite sensor. NOTE: ● To install, reverse the removal procedure sequence.

14.5 - 24.5 (1.5 - 2.5, 11 - 18)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

7 - 13 (0.8 - 1.3, 62 - 115)

NRS126

Removal — Air Bag Module and Spiral Cable SEC. 253⋅484

Special bolt

Audio steering switch (where fitted)

Side lid RH (where fitted)

7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 69 - 121 in-lb)

Side lid RH

29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

Spiral cable

Lower lid Air bag module Combination switch Special bolt Side lid LH

7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 69 - 121 in-lb) NRS123

RS-14

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Air Bag Module and Spiral Cable (Cont’d) CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait for at least 3 minutes. ● Always work from the side of air bag module. 1. Remove lower lid from steering wheel, and disconnect air bag module connector. SBF811E

2. Remove side lids. Using the TAMPER RESISTANT TORX (Size T50), remove left and right special bolts. Air bag module can then be removed.

Special bolt SBF812E

CAUTION: ● Always place air bag module with pad side facing upward. ● Do not attempt to disassemble air bag module. ● The special bolts are coated with bonding agent. Do not use old bolts after removal; replace with new ones. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.

Up

SRS443

● ● Air bag module

●

Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module.

SBF814E

3. Set steering wheel in the neutral position, with the front wheels straight ahead. 4. Disconnect horn connector and remove nut. 5. Using steering wheel puller, remove steering wheel. Be careful not to over-tighten puller bolt on steering wheel. CAUTION: ● Do not tap or bump the steering wheel. 6. Remove steering column cover. SBF239F

RS-15

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Air Bag Module and Spiral Cable (Cont’d) Connector Unlock Lock

7. Disconnect connector and remove the four screws. The spiral cable can then be removed. CAUTION: ● Do not attempt to disassemble spiral cable. ● Do not apply lubricant to the spiral cable.

SRS384

Right end

Installation — Air Bag Module and Spiral Cable 1. Set the front wheels in the straight-ahead position. 2. Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left (clock wise) about 3.5 revolutions from the right end position. Align the two marks ( ) or make sure the white indicator is visible in the upper part of the indicator window, with the cable pointed down wards.

Indicator not visible

Indicator window

CAUTION: The spiral cable may snap during steering operation if the cable is installed incorrectly. ● Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. (The spiral cable can be turned up to 3.5 turns from the neutral position to both the right and left.) 3. Connect spiral cable connector and tighten with screws. Install steering column cover. ●

Indicator is visible

Indicator window Neutral position

NRS121

4. Install steering wheel setting spiral cable pin guides, and pull spiral cable through. 5. Connect horn connector and engage spiral cable with pawls in steering wheel. Move other connectors away from steering wheel lower lid opener. 6. Tighten nut. : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

SRS076

Special bolt 7.8 - 13.7 N·m (0.8 - 1.4 kg-m, 57 - 99 ft-lb)

SBF812EA

7. Position the driver’s air bag module and tighten with new special bolts. ● Always service the air bag module from the side. 8. Connect other connectors. 9. Install all lids and steering switch (where fitted). 10. Connect both battery cables. 11. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.) 12. Turn steering wheel to the left end and then to the right end fully to make sure that spiral cable is set in the neutral position.

RS-16

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Installation — Air Bag Module and Spiral Cable (Cont’d) If air bag warning lamp blinks or stays ON (at the user mode), it shows the spiral cable may be snapped due to its improper position. Perform self-diagnosis again (use CONSULT-II or warning lamp). If a malfunction is detected, replace the spiral cable with a new one. 13. Perform self-diagnosis again to check that no malfunction is detected.

Removal — Front Passenger’s Air Bag Module .

Connector

.

NRS009

.

Remove special bolts

CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. ● Always work from the side of or under air bag module. 1. Open the glove box lid. 2. Disconnect inflator connector from body harness air bag connector. 3. Remove glove box assembly. Refer to “INSTRUMENT PANEL” in BT section for details. 4. Remove the bolts and special bolts using the TAMPER RESISTANT TORX (Size T50) from front passenger’s air bag module. Take out the air bag module from the instrument panel. ● The air bag module is heavy and should be supported using both hands during removal.

.

NRS010

5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)

5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)

NRS124

Bolts Nuts

CAUTION: ● Always place air bag module with pad side facing upward. ● Do not attempt to disassemble air bag module. ● The special bolts are coated with bonding agent. Do not use old bolts after removal; replace with new coated bolts. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.

Passenger’s air bag module NRS011

RS-17

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Front Passenger’s Air Bag Module (Cont’d) ● ●

Air bag module

● ●

Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module. After air bag inflates, the front instrument panel assembly should be replaced if damaged.

SBF814E

5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb)

5.2 - 7.0 N·m (0.53 - 0.71 kg-m, 46 - 61 in-lb) .

Installation — Front Passenger’s Air Bag Module ● Always work from the side of or under air bag module. 1. Install front passenger’s air bag module on steering member. ● Ensure harness is not caught between rear of air bag module and steering member. 2. Install lower instrument panel.

NRS124

15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)

.

.

NRS014

3. Connect air bag module connector to air bag harness connector. 4. Install glove box. 5. Connect both battery cables. 6. Conduct self-diagnosis to ensure entire SRS operates correctly. (Use CONSULT-II or warning lamp check).

Connector

.

NRS009

RS-18

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Side Air Bag Module CAUTION: ● Before servicing SRS, turn the ignition switch “OFF”, disconnect both battery cables and wait at least 3 minutes. 1. Slide the front seat all the way forward. 2. Disconnect side air bag module connector under the seat. (The connector with a different shape is for a side air bag module of Renault make.)

Connector

Connector

NRS064

3. Remove screw securing the front seat convenience hook (where fitted). ● When using a clip removal tool to remove the seat back finisher, take care not to damage the air bag harness. 4. Remove the seat back board.

NRS068

5. Pull up the seat back trim. 6. Remove the bolts securing the inner cloth with seat back frame. Then pull up the inner cloth. 7. Remove the seat back trim. Refer to “Front Seat” in BT section for details.

Inner cloth

6.1 - 7.7 N·m . (0.62 - 0.79 kg-m, 54 - 68 in-lb)

NRS065

.

6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 54 - 68 in-lb)

8. Remove the torx nuts coated with bonding agent from the side air bag module. 9. Remove side air bag connector. Side air bag module can then be removed.

Side air bag module

NRS066

RS-19

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Removal — Side Air Bag Module (Cont’d) CAUTION: ● Always place the air bag module with the stud bolts side facing down. ● Do not attempt to disassemble air bag module. ● The torx nuts are coated with bonding agent. Do not use old nuts after removal; replace with new coated nuts. ● Do not insert any foreign objects (screwdriver, etc.) into air bag module connector.

UP

SRS483

● ● Air bag module

● ●

Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module. After air bag inflates, all parts of front seat back (including front seat back frame) should be replaced.

SBF814E

Installation — Side Air Bag Module

.

6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 54 - 68 in-lb)

1. Install side air bag module on seat back frame with new torx nuts coated with bonding agent.

Side air bag module

NRS066

2. Install the seat back trim. Refer to “Front Seat” in BT-section. 3. Secure the inner cloth which covers the side air bag module with bolts.

Inner cloth

.

6.1 - 7.7 N·m (0.62 - 0.79 kg-m, 53.8 - 68.6 ft-lb)

NRS065

4. Install the seat back board with new clips. 5. Install the front seat convenience hook (where fitted) and secure with screw.

NRS081

RS-20

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Installation — Side Air Bag Module (Cont’d) 6. Connect side air bag module connector. 7. Connect both battery cables. 8. Go to “SRS Operation Check”, RS-37 and perform self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or AIR BAG warning lamp).

Connector

Connector

NRS082

RS-21

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner ●

● ● ●

● ● ● ● ● ● ● ●

Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems, deploy the systems. If such systems have already been deployed due to an accident, dispose of as indicated in “DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER” (RS-27). When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool; Deployment tool KV99106400. When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from deployment component. When deploying air bag module and seat belt pre-tensioner a fairly loud noise is made, followed by smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it irritates the throat and can cause choking. Always activate one air bag module at a time. Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave seat belt pre-tensioner unattended for more than 10 minutes after deployment. Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. Never apply water to a deployed air bag module and seat belt pre-tensioner. Wash your hands clean after finishing work. Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air bag module and seat belt pre-tensioner while mounted in vehicle. Use a voltmeter to make sure the vehicle battery is fully charged. Do not dispose of the air bag module and seat belt pre-tensioner un-deployed.

CHECKING DEPLOYMENT TOOL

Red

Connecting to battery

Black Deployment tool (KV99106400)

SRS019-A

CAUTION: The battery must show voltage of 9.6V or more. Remove the battery from the vehicle and place it on dry wood blocks approximately 5 m (16 ft) away from the vehicle. ● Wait 3 minutes after the vehicle battery is disconnected before proceeding. ● Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. Make sure the polarity is correct. The right side lamp in the tool, marked “deployment tool power”, should glow with a green light. If the right side lamp glows red, reverse the connections to the battery.

RS-22

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Deployment tool check

Lamp

Press the deployment tool push button to the “ON” position. The left side lamp in the tool, marked “air bag connector voltage” should illuminate. If it does not illuminate, replace the tool.

Push

Air bag deployment tool lamp illumination chart (Battery connected)

SBF266H

Switch operation

Left side lamp, green* “AIR BAG CONNECTOR VOLTAGE”

Right side lamp, green* “DEPLOYMENT TOOL POWER”

OFF

OFF

ON

ON

ON

ON

*: If this lamp glows red, the tool is connected to the battery incorrectly. Reverse the connections and make sure the lamp glows green.

DEPLOYMENT PROCEDURES FOR AIR BAG MODULE AND SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE) Unless the vehicle is being scrapped, deploying the air bag module and seat belt pre-tensioner in the vehicle is not recommended. This may cause damage to the vehicle interior. Anchor air bag module and seat belt pre-tensioner in a vise secured to a firm foundation during deployment. Wire

Wire Air bag module bracket [KV99105300]

Deployment of Driver’s Air Bag Module (Outside of vehicle) 1. Using wire, secure air bag module to air bag module bracket [SST: KV99105300] at two places. CAUTION: Use wire of at least 1 mm (0.04 in) diameter. 2. Attach tightly the air bag module bracket [SST: KV99105300] with air bag module in a vise.

SRS233 Wire

Wire

3. Connect deployment tool [SST: KV99106400] to air bag module connector.

Deployment tool [KV99106400] Air bag module connector

Air bag module bracket [KV99105300]

SRS234

4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 5. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 6. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module.

Air bag module

Deployment tool (KV99106400)

SRS235

RS-23

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) 15 (0.59) 15 (0.59)

Deployment of Passenger’s Air bag Module (outside of vehicle)

8.5 (0.335 dia.)

1. Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket [SST: KV99105300] at the position as shown in the left figure. 2. Attach tightly the air bag module bracket [SST: KV99105300] in a vise.

144 (5.67)

Unit: mm (in)

Air bag module bracket [KV99105300]

NRS084

Air bag bracket [KV99105300]

Bolt M 8 x 25 - 30 mm (0.98 - 1.18 in)

3. Match the two holes in air bag module bracket (held in vise) and passenger’s air bag module and fix them with two bolts [M8 x 25 - 30 mm (0.98 - 1.18 in)]. CAUTION: If a gap exists between passenger’s air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module.

NRS022

4. Connect deployment tool adapter [SST: KV99108300] to deployment tool [SST: KV99106400] connector and air bag module connector.

Deployment tool adapter Deployment tool [KV99108300] [KV99106400]

.

NRS023

Air bag module

Deployment tool [KV99106400]

SRS020-B

.

6.5 (0.256) dia.

13 (0.51)

5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 6. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module and do not stand on the deploying side.

Deployment of Side Air bag Module (outside of vehicle) 1. Make 6.5 mm (0.256 in) diameter holes in air bag module bracket [SST: KV99105300] at the position as shown on the left figure.

(2.76)

Unit: mm (in)

(3.15)

Air bag module bracket [KV99105300] SRS490

RS-24

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Front side air bag module UP

Metal portion M6 nut

Air bag module bracket [KV99105300]

SRS491

Deployment tool KV99106400]

Deployment tool adapter [KV99108300]

2. Attach tightly the air bag module bracket [SST: KV99105300] in a vise. 3. Insert the stud bolts of side air bag module into the two holes in air bag module bracket held in vise and fix them with two M6 nuts. CAUTION: Side air bag module should be secured to air bag module bracket [SST: KV99105300] in a vise with metal portion facing down. 4. Connect deployment tool adapter [SST: KV99108300] to deployment tool [SST: KV99106400] connector and connector on air bag module.

SRS492

5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 6. The lamp on the right side of the tool, marked “deployment tool power” should glow green, not red. 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illumminate and the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module.

Air bag module

Deployment tool [KV99106400]

SRS020-A

Deployment of seat belt pre-tensioner (outside of vehicle) Firmly place pre-tensioner and webbing in the vise

1. Firmly anchor seat belt pre-tensioner in a vise. CAUTION: Ensure bracket and webbing are place in the vise.

SBF272H

Deployment tool adapter (KV99108200)

2. Connect deployment tool adapter [SST: KV99108200] to deployment tool [SST: KV99106400] connector and seat belt pre-tensioner connector.

Deployment tool (KV99106400)

NRS025

RS-25

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Deployment tool (KV99106400)

SRS021-A

3. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 4. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 5. Press the button on the deployment tool. The left side lamp on the tool, marked “seat belt pre-tensioner connector voltage”, will illuminate and the seat belt pre-tensioner will deploy. CAUTION: When deploying the seat belt pretensioner, stand at least 5 m (16 ft) away from the seat belt pre-tensioner.

DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE

SBF811E

.

Deployment tool [KV99106400]

SRS006

When disposing of a vehicle, deploy air bag modules and seat belt pre-tensioners while they are mounted in vehicle. CAUTION: When deploying air bag modules or seat belt pre-tensioner, ensure vehicle is empty. 1. Disconnect both the vehicle battery cables and wait 3 minutes. 2. Disconnect air bag modules and seat belt pre-tensioners connector. 3. Connect deployment tool [SST: KV99106400] to air bag module or seat belt pre-tensioner. For front passenger’s air bag module and front side air bag module (built-in type), attach deployment tool adapter [SST: KV99108300] to the tool connector. For seat belt pre-tensioner attach deployment tool adapter [SST: KV99108200]. 4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 5. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 6. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module or seat belt pre-tensioner will deploy. CAUTION: Activate only one passenger’s air bag module or seat belt pre-tensioner at a time.

RS-26

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER

SBF276H

Deployed air bag modules and seat belt pre-tensioners are very hot. Before disposing of air bag module, and seat belt pretensioner, wait at least 30 minutes, and 10 minutes, respectively. Seal them in a plastic bag before disposal. CAUTION: ● Never apply water to a deployed air bag module and seat belt pre-tensioner. ● Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. ● No poisonous gas is produced upon air bag module deployment. However, be careful not to inhale gas since it irritates throat and can cause choking. ● Do not attempt to disassemble air bag module and seat belt pre-tensioner. ● Air bag module and seat belt pre-tensioner cannot be re-used. ● Wash your hands clean after finishing work.

RS-27

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction CAUTION: ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER CONNECTOR”) can be identified by yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors. ● Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged, replace it with a new one. ● Keep ground portion clean.

DIAGNOSIS FUNCTION The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp and/or CONSULT-II. The reading of these results is accomplished using one of two modes — “User mode” and “Diagnosis mode”. The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system malfunction through the operation of the “AIR BAG” warning lamp. The Diagnosis mode allows the technician to locate and inspect the malfunctioning part. The mode applications for the “AIR BAG” warning lamp and CONSULT-II are as follows:

●

User mode

Diagnosis mode

Display type

“AIR BAG” warning lamp

X

X

ON-OFF operation

CONSULT-II

—

X

Monitoring

Seat belt pre-tensioner system can only be diagnosed by CONSULT-II.

DIAGNOSIS MODE FOR CONSULT-II ●

●

●

●

SELF-DIAG [CURRENT] A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diagnosis mode) is displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring repairs. SELF-DIAG [PAST] Diagnosis results previously stored in the memory (also indicated by the warning lamp flashes in the Diagnosis mode) are displayed on the CONSULT-II screen. The stored results are not erased until memory erasing is executed. TROUBLE DIAG RECORD With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen. “ECU DISCRIMINATED NO.” The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number (refer to the table below). This number will be displayed on the CONSULT-II screen. When replacing the diagnosis sensor unit, refer to the part number for the compatibility. After installation, replacement with a correct unit can be checked by confirming this classification number on the CONSULT-II screen.

For NISSAN MODEL P11, the diagnosis sensor unit classification numbers are as follows: MODEL

ECU DISCRIMINATED NO.

Models with single air bag and seat belt pre-tensioner

A914

Models with dual air bags and seat belt pre-tensioner

A915

Models with dual air bags, side air bag and seat belt pre-tensioner

A916

RS-28

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction (Cont’d) HOW TO CHANGE SELF-DIAGNOSIS MODE With CONSULT-II From User mode to Diagnosis mode After selecting AIR BAG on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis mode.

“AIRBAG” warning lamp operation indicates Diagnosis mode.

NRS115

From Diagnosis mode to User mode To return to User mode from diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears. Diagnosis mode automatically changes to User mode.

“AIRBAG” warning lamp operation indicates User mode.

NRS116

How to Change Self-diagnosis Mode without CONSULT-II From User Mode to Diagnosis Mode Diagnosis mode activates only when a malfunction is detected, by turning ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 three times. 5) Turn ignition switch “ON”. SRS will not enter Diagnosis mode, if no malfunction is detected.

From Diagnosis Mode to User Mode After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode is returned to User mode. If switching Diagnosis mode to User mode is required while malfunction is being detected, by turning ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 three times. 5) Turn ignition switch “ON”.

RS-29

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses Introduction (Cont’d) HOW TO ERASE SELF-DIAGNOSIS RESULTS With CONSULT-II ●

“SELF-DAIG [CURRENT]” A current Self-diagnosis result is displayed on the CONSULT-II screen in real time. After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”.

“SELF-DIAG [PAST]” Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen by pushing “BACK” key of CONSULT-II and select “SELFDIAG [CURRENT]” in “SELECT DIAG MODE”. Touch “ERASE” in “SELF-DIAG [CURRENT]” mode. NOTE: If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. ●

C2SDC02

●

“TROUBLE DIAG RECORD” The memory of “TROUBLE DIAG RECORD” cannot be erased. Without CONSULT-II

After a malfunction is repaired, return to User mode from Diagnosis mode by switching the ignition “OFF” for at least 1 second, then back “ON”. Diagnosis mode returns to the User mode. At that time, self-diagnosis result is cleared.

How to Perform Trouble Diagnoses for Quick and Accurate Repair A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint.

INFORMATION FROM CUSTOMER WHAT ....... WHEN ...... WHERE .... HOW ........

Vehicle model Date, Frequencies Road conditions Operating conditions, Symptoms

PRELIMINARY CHECK Check that the following parts are in good order. ● Battery [Refer to EL section (“BATTERY”).] ● Fuse [Refer to EL section (“Fuse”, “POWER SUPPLY ROUTING”).] ● System component-to-harness connections

RS-30

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d)

ACTION ITEM

REFERENCE ITEM

Check in

H

Listen to customer complaints and requests.

H

Perform preliminary check.

F

Preliminary check (RS-30)

F

SRS Operation Check DIAGNOSTIC PROCEDURE 1 (RS-37)

H

Check for any Service Bulletin.

H

Check air bag system operation by using “AIR BAG” warning lamp. — User mode

H E

Inspect malfunctioning part. — Diagnosis mode

F

Perform self-diagnosis using CONSULT-II. ------------------------------------------------------------------------------------------------------------------ OR -----------------------------------------------------------------------------------------------------------------Perform self-diagnosis using “AIR BAG” warning lamp.

● ●

DIAGNOSTIC PROCEDURE 2: Using CONSULT-II (RS-38) DIAGNOSTIC PROCEDURE 6: Using “AIR BAG” warning lamp (RS-48)

H

Repair/Replace

NG

H

Final check — Diagnosis mode and User mode OK

F

● ●

H

Check out

RS-31

DIAGNOSTIC PROCEDURE 3: Using CONSULT-II (RS-42) DIAGNOSTIC PROCEDURE 7: Using “AIR BAG” warning lamp (RS-53)

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Schematic

YRS058

RS-32

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS —

YRS059

RS-33

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)

DIAGNOSIS SENSOR UNIT

SPIRAL CABLE AIR BAG MODULE (PASSENGER’S SIDE)

AIR BAG MODULE (DRIVER’S SIDE)

: With dual air bag

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YRS049

RS-34

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)

YRS060

RS-35

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Wiring Diagram — SRS — (Cont’d)

YRS061

RS-36

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) SRS-Operation Check DIAGNOSTIC PROCEDURE 1 Checking Air Bag Operation by using “AIR BAG” Warning Lamp — User mode 1. After turning ignition switch from “OFF” to “ON”, “AIR BAG” warning lamp operates. 2. Compare “AIR BAG” warning lamp operation to the chart below. SRS800

“AIR BAG” warning lamp operation — User mode —

SRS condition No malfunction is detected. No further action is necessary.

IGN ON ON OFF

Reference item

— 7 sec.

MRS095A IGN ON ON

The system is malfunctioning and needs to be repaired as indicated.

Go to DIAGNOSTIC PROCEDURE 2, or 6 (RS-38 or 48 ).

Air bag or/and seat belt pre-tensioner is deployed.

Go to COLLISION DIAGNOSIS (RS-57).

Air bag fuse, diagnosis sensor unit or harness is malfuncitoning and needs to be repaired.

Go to DIAGNOSTIC PROCEDURE 9 (RS-56).

One of the following has occurred and needs to be repaired. ● Meter fuse is blown. ● “AIR BAG” warning lamp circuit has open or short. ● Diagnosis sensor unit is malfunctioning.

Go to DIAGNOSTIC PROCEDURE 10 (RS56).

OFF 0.5 sec.

0.5 sec.

MRS096A IGN ON ON OFF

MRS097A IGN ON ON OFF

MRS098A

NOTE: If “AIR BAG” warning lamp operates differently from the operations shown above, refer to “AIR BAG” warning lamp operation — Diagnosis mode —, DIAGNOSTIC PROCEDURE 6 (step 4), RS-48.

RS-37

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II

Data link connector

DIAGNOSTIC PROCEDURE 2 Inspecting SRS malfunctioning parts by using CONSULT-II — Diagnosis mode 1. Turn ignition switch to the “OFF”. 2. Connect “CONSULT-II” to Data link connector.

NRS071

3. Turn ignition switch “ON”. 4. Touch “START”.

SRS695

5. Touch “AIRBAG”.

C2SSE01

6. Touch “SELF-DIAG [CURRENT]”.

C2SDM02

7. Diagnostic codes are displayed on “SELF-DIAG [CURRENT]”.

SRS772

RS-38

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [CURRENT]” but malfunction is indicated by the “AIR BAG”, warning lamp, go to DIAGNOSTIC PROCEDURE 4, page RS-43, to diagnose the following situations: ● Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. ● The SRS system malfunctions intermittently.

C2SDC02

8. Touch “PRINT”. 9. Compare diagnostic codes to “CONSULT-II Diagnostic Code Chart”, page RS-39. 10. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM ” appears in order to return to User mode from Diagnosis mode. 11. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II and both battery cables. 12. Repair the system as outlined by the “Repair order” in “CONSULT-II Diagnostic Code Chart”, that corresponds to the selfdiagnostic result. For replacement procedure of component parts, refer to RS-13. 13. After repairing the system, go to DIAGNOSTIC PROCEDURE 3, page RS-42 for final checking.

CONSULT-II Diagnostic Code Chart (“SELF-DIAGNOSIS”) Diagnostic item NO DTC IS DETECTED.

When malfunction is indicated by the “AIR BAG” warning lamp in User mode

●

Low battery voltage (Less than 9V).

Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. ● Intermittent malfunction has been detected in the past. ●

No malfunction is detected. AIRBAG MODULE [OPEN]

Repair order Recheck SRS at each replacement.

Explanation

●

Driver’s air bag module circuit is open. (including the spiral cable)

RS-39

●

Go to DIAGNOSTIC PROCEDURE 3 (RS-42) after charging battery.

Go to DIAGNOSTIC PROCEDURE 4 (RS-43).

●

Go to DIAGNOSTIC PROCEDURE 3 (RS-42).

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace driver’s air bag module. (Before disposing of it, it must be deployed.) 4. Replace the spiral cable. 5. Replace the diagnosis sensor unit. 6. Replace the related harness.

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item

Explanation

AIRBAG MODULE [VB-SHORT]

●

Driver’s air bag module circuit is shorted to a power supply circuit. (including the spiral cable)

AIRBAG MODULE [GND-SHORT]

●

Driver’s air bag module circuit is shorted to ground. (including the spiral cable)

AIRBAG MODULE [SHORT]

●

Driver’s air bag module circuits are shorted to each other.

ASSIST A/B MODULE [VB/SHORT]

●

Passenger’s air bag module circuit is shorted to some power supply circuit.

ASSIST A/B MODULE [OPEN]

●

Passenger’s air bag module circuit is open.

ASSIST A/B MODULE [GND-SHORT]

●

Passenger’s air bag module circuit is shorted to ground.

ASSIST A/B MODULE [SHORT]

●

Passenger’s air bag module circuits are shorted to each other.

SIDE MODULE LH [OPEN]

●

Side air bag module (LH) circuit is open.

SIDE MODULE LH [VB-SHORT]

●

Side air bag module (LH) circuit is shorted to some power supply circuits.

SIDE MODULE LH [GND-SHORT]

●

Side air bag module (LH) circuit is shorted to ground.

SIDE MODULE LH [SHORT]

●

Side air bag module (LH) circuits are shorted to each other.

SIDE MODULE RH [OPEN]

●

Side air bag module (RH) circuit is open.

SIDE MODULE RH [VB-SHORT]

●

Side air bag module (RH) circuit is shorted to some power supply circuits.

SIDE MODULE RH [GND-SHORT]

●

Side air bag module (RH) circuit is shorted to ground.

SIDE MODULE RH [SHORT]

●

Side air bag module (RH) circuits are shorted to each other.

SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL]

●

Satellite sensor (LH)

Repair order Recheck SRS at each replacement. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the spriral cable. 4. Replace driver’s air bag module. (Before disposing of it, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger’s air bag module. (Before disposal of it, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the side air bag module (LH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the side air bag module (RH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the satellite sensor (LH). 4. Replace the diagnosis sensor unit. 5. Replace the related harness.

RS-40

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item

Repair order Recheck SRS at each replacement.

Explanation

SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL]

●

Satellite sensor (RH)

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the satellite sensor (RH). 4. Replace the diagnosis sensor unit. 5. Replace the related harness.

PRE-TEN LH [OPEN/VB-SHORT]

●

The circuit for LH pre-tensioner is open or shorted to some power supply circuit.

PRE-TEN LH [GND-SHORT]

●

The circuit for LH pre-tensioner is shorted to ground.

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace LH seat belt. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit 5. Replace the related harness.

PRE-TEN RH [OPEN/VB-SHORT]

●

The circuit for RH pre-tensioner is open or shorted to some power supply circuit.

PRE-TEN RH [GND-SHORT]

●

The circuit for RH pre-tensioner is shorted to ground.

CONTROL UNIT

●

Low battery voltage or diagnosis sensor unit is out of order.

1. Charge battery. 2. Visually check wiring harness connections. 3. Replace diagnosis sensor unit.

CONTROL UNIT

●

Low battery voltage (Less than 9V)

●

●

Diagnosis sensor unit is malfunctioning.

1. Visually check wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace diagnosis sensor unit. 4. Replace the related harness.

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace RH seat belt. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit 5. Replace the related harness.

Go to DIAGNOSTIC PROCEDURE 3 (RS-42) to after charging battery.

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the air bag warning lamp or CONSULT-II each time repair is finished. If malfunction is still observed, proceed to the next step. When malfunction is eliminated, further repair work is not required.

RS-41

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Data link connector DIAGNOSTIC PROCEDURE 3 Final checking after repairing SRS by using CONSULT-II — Diagnosis mode 1. After repairing SRS, connect both battery cables. 2. Connect CONSULT-II to Data link connector. 3. Turn ignition switch from “OFF” to “ON”.

NRS071

4. Touch “START”.

SRS695

5. Touch “AIRBAG”.

C2SSE01

6. Touch “SELF-DIAG [CURRENT]”.

C2SDM02

7. If no malfunction is detected on “SELF-DIAG [CURRENT]”, repair of SRS is completed. Go to step 8. If any malfunction is displayed on “SELF-DIAG [CURRENT]”, the malfunctioning part is not repaired completely or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 2, page RS-38, and repair malfunctioning part completely.

C2SDC02

RS-42

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) 8. Touch “ERASE”. NOTE: Touch “ERASE” to clear the memory of the malfunction (“SELF-DIAG [PAST]”). If the memory of the malfunction in “SELF-DIAG [PAST] is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. C2SDC01

9. Touch “BACK” key of CONSULT-II to “SELECT SYSTEM” screen. Touch “SELF-DIAG [PAST]”.

C2SDM02

10. Check that no malfunction is detected on “SELF-DIAG [PAST]”.

C2SDP02

11. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. 12. Turn ignition switch “OFF” then turn off and disconnect CONSULT-II. 13. Go to “SRS Operation Check”, page RS-37 to check SRS operation by using “AIR BAG” warning lamp with User mode.

DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) Inspecting SRS malfunctioning record Is it the first time for maintenance of SRS? Yes

H

Go to DIAGNOSTIC PROCEDURE 5 (RS-44).

RS-43

No E

Self-diagnostic results “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 3, step 8 (RS-42).

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Data link connector DIAGNOSTIC PROCEDURE 5 Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode 1. Turn ignition switch “OFF”. 2. Connect CONSULT-II to Data link connector.

SRS701

3. Turn ignition switch “ON”. 4. Touch “START”.

SRS695

5. Touch “AIR BAG”.

C2SSE01

6. Touch “SELF-DIAG [PAST]”.

C2SDM02

7. If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to step 10.

C2SDP01

RS-44

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [PAST]”, touch “BACK” and go back to “SELECT DIAG MODE”.

C2SDP02

8. Touch “TROUBLE DIAG RECORD”. NOTE: With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed.

C2SDM02

9. Diagnostic code RECORD”.

is

displayed

on

“TROUBLE

DIAG

C2TDR02

10. Touch “PRINT”. 11. Compare diagnostic codes to “Intermittent Malfunction Diagnostic Code Chart”, page RS-46. 12. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears. 13. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II, and both battery cables. 14. Repair the system as outlined by the “Repair order” in “Intermittent Malfunction Diagnostic Code Chart”, that corresponds to the self-diagnostic result. For replacement procedure of component parts, refer to RS-13. 15. Go to DIAGNOSTIC PROCEDURE 3, page RS-42, for final checking.

RS-45

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Intermittent Malfunction Diagnostic Code Chart (“SELF DIAG [PAST]” or “TROUBLE DIAG RECORD”) Diagnostic item NO DTC IS DETECTED.

Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode

●

Low battery voltage (Less than 9V).

No malfunction is detected. AIRBAG MODULE [OPEN]

●

Driver’s air bag module circuit is open. (including the spiral cable)

AIRBAG MODULE [VB-SHORT]

●

Driver’s air bag module circuit is shorted to some power supply circuit. (including the spiral cable)

AIRBAG MODULE [GND-SHORT]

●

Driver’s air bag module circuit is shorted to ground. (including the spiral cable)

AIRBAG MODULE [SHORT]

●

Driver’s air bag module circuits are shorted to each other.

ASSIST A/B MODULE [VB/SHORT]

●

Passenger’s air bag module circuit is shorted to some power supply circuit.

ASSIST A/B MODULE [OPEN]

●

Passenger’s air bag module is open.

ASSIST A/B MODULE [GND-SHORT]

●

Passenger’s air bag module circuit is shorted to ground.

ASSIST A/B MODULE [SHORT]

●

Passenger’s air bag module circuits are shorted to each other.

SIDE MODULE LH [OPEN]

●

Side air bag module (LH) circuit is open.

SIDE MODULE LH [VB-SHORT]

●

Side air bag module (LH) circuit is shorted to some power supply circuits.

SIDE MODULE LH [GND-SHORT]

●

Side air bag module (LH) circuit is shorted to ground.

SIDE MODULE LH [SHORT]

●

Side air bag module (LH) circuits are shorted to each other.

SIDE MODULE RH [OPEN]

●

Side air bag module (RH) circuit is open.

SIDE MODULE RH [VB-SHORT]

●

Side air bag module (RH) circuit is shorted to some power supply circuits.

SIDE MODULE RH [GND-SHORT]

●

Side air bag module (RH) circuit is shorted to ground.

SIDE MODULE RH [SHORT]

●

Side air bag module (RH) circuits are shorted to each other.

SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL]

●

Satellite sensor (LH)

Repair order ●

Go to DIAGNOSTIC PROCEDURE 3 (RS-42) after charging battery.

●

Go to DIAGNOSTIC PROCEDURE 3 (RS-42).

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace driver’s air bag module (Before disposal of it, it must be deployed.), diagnosis sensor unit and spiral cable. 1. Visually check the wiring harness connection. 2. Replace the air bag harness if it has visible damage. 3. If the harness check result is OK, replace front air bag module (Before disposal of it, it must be deployed.), and diagnosis sensor unit. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and side air bag module (LH). (Before disposing the side air bag module (LH), it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and side air bag module (RH). (Before disposing the side air bag module (RH), it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (LH).

RS-46

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item

Explanation

Repair order

SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL]

●

Satellite sensor (RH)

1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and satellite sensor (RH).

PRE-TEN LH [OPEN/VB-SHORT]

●

The circuit for LH seat belt pre-tensioner is open or shorted to some power supply circuit.

PRE-TEN LH [GND-SHORT]

●

The circuit for LH seat belt pre-tensioner is shorted to ground.

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and LH seat belt. (Before disposing the LH seat belt pre-tensioner, if must be deployed.)

PRE-TEN RH [OPEN/VB-SHORT]

●

The circuit for RH seat belt pre-tensioner is open or shorted to some power supply circuit.

PRE-TEN RH [GND-SHORT]

●

The circuit for RH seat belt pre-tensioner is shorted to ground.

CONTROL UNIT

●

Diagnosis sensor unit is malfunctioning.

1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and RH seat belt. (Before disposing the RH seat belt pre-tensioner, if must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit.

* Follow the procedures in numerical order when repairing malfunctioning parts, then make the final system check.

RS-47

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II DIAGNOSTIC PROCEDURE 6

SRS800

Inspecting SRS malfunction parts by using “AIR BAG” warning lamp — Diagnosis mode NOTE: SRS will not enter Diagnosis mode if no malfunction is detected in User mode. 1. Turn ignition switch “ON”. 2. After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3. Wait more than 3 seconds. 4. Repeat steps 1 to 3 three times. 5. Turn ignition switch “ON”. SRS is now in Diagnosis mode. 6. “AIR BAG” warning lamp operates in Diagnosis mode as follows: NOTE: If SRS does not enter Diagnosis mode even though malfunction is detected in User mode, check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to DIAGNOSTIC PROCEDURE 7, page RS-53. If the battery voltage is OK, replace the diagnosis sensor unit.

RS-48

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No.

“AIR BAG” warning lamp flash pattern — Diagnosis mode — a p

through

SRS condition b p

are repeated.

IGN ON ON OFF 3 sec.

7 sec.

2 sec.

1

SRS333

a p b p

through p d are repeated. — Driver and passenger’s air bag marker (For identifying driver’s passenger’s air bag and/or front seat belt pre-tensioner malfunctioning) d — Indicates malfunctioning p part. The number of flash varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

IGN ON ON OFF

2

3 sec.

7 sec. 2 sec.

2 sec.

Diagnosis results (previously stored in the memory) might not be erased after repair. ● Intermittent malfunction has been detected in the past. Go to DIAGNOSTIC PROCEDURE 8 (RS-55). ●

The system is malfunctioning and needs to be repaired.

SRS341 a through p f are repeated. p b , c , d — Side air bag p p p

IGN ON ON

marker (For identifying side air bag malfunctioning) pf — Indicates malfunctioning part. The number of flash varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

OFF

3

7 sec.

2 sec. 2sec. 1.5 sec. 1.5 sec. 0.5 sec.

SRS342-A

7. Malfunctioning part is indicated by the number of flashes (part p d or p f ). Compare the number of flashes to “Air Bag Warning Lamp Flash Code Chart”, page RS-50, and locate malfunctioning part. 8. Turn ignition switch “OFF”, and disconnect both battery cables. 9. Repair the system as outlined by the “Repair order” in “Warning Lamp Flash Code Chart” that corresponds to the flash code. For replacement procedure of component parts, refer to RS-13. 10. After repairing the system, go to DIAGNOSTIC PROCEDURE 7, page RS-53.

RS-49

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Air Bag Warning Lamp Flash Code Chart (Diagnosis mode) Flash pattern IGN ON ●

●

Diagnosis results (previously stored in the memory) might not be erased after repair. Intermittent malfunction has been detected in the past.

ON

a p

through p b are repeated.

OFF 3 sec.

7 sec.

2 sec. SRS333

Repair order ●

Go to DIAGNOSTIC PROCEDURE 8 (RS-55). Flash pattern IGN ON a p

through p d are repeated. d — Two flashes p indicated malfunctioning driver’s air bag module circuit.

ON OFF 3 sec.

7 sec.

The driver’s air bag module circuit is malfunctioning. (p d : 2 flashes)

2 sec.

2 sec. SRS334

Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4.

Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the spiral cable. Replace driver’s air bag module. (Before disposal, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. Flash pattern IGN ON a p

through p d are repeated. d — Seven p flashes indicate malfunctioning diagnosis sensor unit.

ON OFF 2 sec.

7 sec.

The diagnosis sensor unit is malfunctioning. (p d : 7 flashes)

2 sec.

1.5 sec. SRS335

Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4.

Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the diagnosis sensor unit. Replace the related harness.

RS-50

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON

a p

through p d are repeated. d — Eight p flashes indicated malfunctioning passenger’s air bag module circuit.

ON OFF

The passenger’s air bag module circuit is malfunctioning. d : 8 flashes) (p

3 sec.

7 sec.

2 sec.

2 sec.

SRS336

Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace passenger’s air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern

IGN ON

a p

through p d are repeated. d — One flash p indicates malfunctioning RH seat belt pre-tensioner circuit.

ON OFF 3 sec.

7 sec.

The RH seat belt pre-tensioner circuit is malfunctioning. (p d 1 flash)

2 sec.

2 sec.

SRS801

Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace RH seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p

through p d are repeated. d — Three flash p indicates malfunctioning LH seat belt pre-tensioner circuit.

ON OFF 7 sec.

The LH seat belt pre-tensioner circuit is malfunctioning. (p d 3 flash)

3 sec. 2 sec.

2 sec.

SRS802

Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace LH seat belt pre-tensioner. (Before disposing, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness.

RS-51

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON a p

through p f are repeated. pf — One flash indicates malfunctioning side air bag module (RH) circuit.

ON OFF 2 sec.

7 sec.

The side air bag module (RH) circuit is malfunctioning. (p f : 1 flash)

2 sec. 1.5 sec. 0.5 sec.1.5 sec. SRS338

Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace side air bag module (RH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p

through p f are repeated. pf — Two flashes indicate malfunctioning side air bag module (LH) circuit.

ON OFF 7 sec.

The side air bag module (LH) circuit is malfunctioning. (p f : 2 flashes)

2 sec. 2 sec. 1.5 sec.

1.5 sec. 0.5 sec. SRS337

Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace side air bag module (LH). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern IGN ON a p

through p f are repeated. pf — Three flashes indicated malfunctioning satellite sensor (RH) circuit.

ON OFF 7 sec.

The satellite sensor (RH) is malfunctioning. (p f : 3 flashes)

2 sec. 2 sec. 1.5 sec.

0.5 sec. 1.5 sec. SRS340

Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5.

Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the satellite sensor (RH). Replace the diagnosis sensor unit. Replace the related harness.

RS-52

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern IGN ON a p

through p f are repeated. pf — Four flashes indicate malfunctioning satellite sensor (LH) circuit.

ON OFF 2 sec.

7 sec.

The satellite sensor (LH) is malfunctioning. (p f : 4 flashes)

2 sec. 1.5 sec. 1.5 sec. 0.5 sec. SRS339-A

Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5.

Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the satellite sensor (LH). Replace the diagnosis sensor unit. Replace the related harness.

* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the air bag warning lamp or CONSULT-II each time repair is finished. If malfunction is still observed, proceed to the next step. When malfunction is eliminated, further repair work is not required.

DIAGNOSTIC PROCEDURE 7 Final checking after repairing SRS by using “AIR BAG” warning lamp — Diagnosis mode and User mode 1. After repairing SRS connect both battery cables. 2. Turn ignition switch from “OFF” to “ON”. 3. “AIR BAG” warning lamp operates in Diagnosis mode as follows:

SRS800

RS-53

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No.

“AIR BAG” warning lamp flash pattern — Diagnosis mode — a p

through

SRS condition b p

are repeated.

IGN ON ON

1 OFF 3 sec.

7 sec.

2 sec.

No malfunction is detected or repair is completed. No further action is necessary.

SRS333 a p b p

IGN ON ON OFF

2

3 sec.

7 sec. 2 sec.

2 sec.

SRS341

The system is malfunctioning and needs to be repaired.

a through p f are repeated. p b , c , d — Side air bag p p p

IGN ON ON

marker (For identifying side air bag malfunctioning) pf — Indicates malfunctioning part. The number of flashes varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

OFF

3

through p d are repeated. — Driver, passenger’s air bag, seat belt pre-tensioner marker (For identifying driver’s, passenger’s air bag and/or seat belt pre-tensioner malfunctioning) d — Indicates malfunctioning p part. The number of flashes varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.)

7 sec.

2 sec. 2sec. 1.5 sec. 0.5 sec.1.5 sec.

SRS342-A

NOTE: When diagnosis sensor unit is replaced with a new one, “AIR BAG” warning lamp will operate in User mode. Checking “AIR BAG” warning lamp operation in Diagnosis mode is not required. Go to step 6. 4. If “AIR BAG” warning lamp operates as shown in No. 1 in chart above, turn ignition switch “OFF” to reset from Diagnosis mode to User mode and to erase memory of the malfunction. Then go to step 6. If “AIR BAG” warning lamp operates as shown in No. 2 or No. 3 in chart above, the malfunctioning part is not repaired completely, or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 6, page RS-48, and repair malfunctioning part completely. 5. Turn ignition switch “ON”. “AIR BAG” warning lamp operates in User mode. Compare “AIR BAG” warning lamp operation to the chart on the next page. NOTE: When a malfunction is detected, switch from Diagnosis mode to user mode by turning the ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second.

RS-54

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 three times. 5) Turn ignition switch “ON”. SRS is now in User mode. “AIR BAG” warning lamp operation — User mode —

SRS condition No malfunction is detected. No further action is necessary.

IGN ON ON OFF

Reference item

— 7 sec.

MRS095A IGN ON ON

The system is malfunctioning and needs to be repaired as indicated.

Go to DIAGNOSTIC PROCEDURE 6 (RS-48).

Air bag and/or seat belt pre-tensioner is deployed.

Go to COLLISION DIAGNOSIS (RS-57).

Air bag fuse, diagnosis sensor unit or harness is malfunctioning and needs to be repaired.

Go to DIAGNOSTIC PROCEDURE 9 (RS-56).

One of the following has occurred and needs to be repaired. ● Meter fuse is blown. ● “AIR BAG” warning lamp circuit has open or short. ● Diagnosis sensor unit is malfunctioning.

Go to DIAGNOSTIC PROCEDURE 10 (RS56).

OFF 0.5 sec.

0.5 sec.

MRS096A IGN ON ON OFF

MRS097A

IGN ON ON OFF

MRS098A

DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) Inspecting SRS malfunctioning record Is it the first time for maintenance of SRS? Yes

H

Go to DIAGNOSTIC PROCEDURE 5 (RS-44). (Further inspection cannot be performed without CONSULT-II).

RS-55

No

E

Diagnosis results (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 7, step 5 (RS-53).

TROUBLE DIAGNOSES — Supplemental Restraint System (SRS) Trouble Diagnoses for Air Bag Warning Lamp

FUSE

DIAGNOSTIC PROCEDURE 9 AIR BAG

SYMPTOM: “AIR BAG” warning lamp does not turn off. Up side

Is air bag module deployed?

Yes E

Replace or repair SRS components. Refer to COLLISION DIAGNOSIS, (RS-57).

E

Replace fuse and turn ignition switch ON. If SRS “Air Bag” fuse is blown again, repair related harness.

E

Visually check the wiring harness connection of diagnosis sensor unit. If the harness connection check is OK, replace diagnosis sensor unit.

E

Connect warning lamp and diagnosis sensor unit properly. If warning lamp still does not go off, replace harness.

No H YRS036

Is SRS “Air Bag” fuse OK?

No

Yes

H

Connect CONSULT-II and touch “START”. ● Is “AIRBAG” displayed on CONSULT-II?

No

Yes H C2SSE01

Is harness connection between warning lamp and diagnosis sensor unit OK?

No

Yes

H

Replace diagnosis sensor unit.

DIAGNOSTIC PROCEDURE 10 FUSE

SYMPTOM: “AIR BAG” warning lamp does not turn on. METER

Is warning lamp fuse OK?

No E

Replace fuse and turn ignition swtich ON. If meter fuse is blown again, repair related harness.

E

Replace warning lamp LED.

E

Connect warning lamp and diagnosis sensor unit properly. If warning lamp still does not come on, replace harness.

Yes Up side

H

Is warning lamp LED OK?

No

Yes YRS038

H

1. Disconnect diagnosis sensor unit connector. 2. Turn the ignition key to ON position. ● Does warning lamp turn on? Yes H

Replace diagnosis sensor unit.

RS-56

No

COLLISION DIAGNOSIS FOR FRONTAL COLLISION To repair the SRS for a frontal collision, perform the following steps. When SRS (except the side airbag) is activated in a collision: 1 Replace the diagnosis sensor unit. p 2 Remove the air bag modules (except the side airbag module) and seat belt pre-tensioner assemblies. p 3 Check the SRS components using the table shown below: p ● Replace any SRS components showing visible signs of damage (dents, cracks, deformation). 4 Install new air bag modules (except the side airbag module) and seat belt pre-tensioner assemblies. p 5 Conduct self-diagnosis using CONSULT-II, and “AIR BAG” warning lamp. Refer to “SRS Operation p Check” for details (RS-37). Ensure entire SRS operates properly. When SRS is not activated in a collision: 1 Check the SRS components using the table shown below: p ● Replace any SRS components showing visible signs of damage (dents, cracks, deformation). 2 p Conduct self-diagnosis using CONSULT-II, and “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-37). Ensure entire SRS operates properly.

SRS inspection Part

SRS (except the side air bag) is activated

SRS is NOT activated

Air bag module (driver’s and passenger’s side)

REPLACE Install air bag module with new bolts coated with bonding agent.

1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2-1. Install driver’s air bag module into the steering wheel to check fit and alignment with the wheel. 2-2. Install passenger’s air bag module into the instrument panel to check fit with the instrument panel. 3. No damage found, reinstall with new bolts coated with bonding agent. 4. If damaged—REPLACE. Install airbag modules with new special bolt coated with bonding agent. Air bag must be deployed before discarding.

Seat belt pre-tensioner assembly

REPLACE Install seat belt pretensioner with new bolts coated with bonding agent.

1. Remove seat belt pre-tensioners. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. Check belts for damage and anchors for loose mounting. 3. Check retractor for smooth operation. 4. If no damage is found, reinstall with new bolts coated with bonding agent. 5. If damaged—REPLACE. Install the seat belt pre-tensioners with new bolts coated with bonding agent. Seat belt pre-tensioners must be deployed before discarding.

Diagnosis sensor unit

REPLACE Install diagnosis sensor unit with new bolts coated with bonding agent.

1. Check case and bracket for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall with new special bolts and ground bolt coated with bonding agent. 4. If damaged—REPLACE. Install diagnosis sensor unit with new bolts and ground bolt coated with bonding agent.

Steering wheel

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

Visually check steering wheel for deformities. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities. Install driver’s air bag module to check fit or alignment with steering wheel. Check steering wheel for excessive free play. If no damage is found, reinstall the steering wheel. If damaged—REPLACE.

Spiral cable

1. 2. 3. 4. 5.

Visually check spiral cable and combination switch for damage. Check connectors, flat cable and protective tape for damage. Check steering wheel for noise, binding or heavy operation. If no damage is found, reinstall the spiral cable. If damaged—REPLACE.

Harness and Connectors

1. 2. 3. 4.

Check connectors for poor connection, damage, and terminals for deformities. Check harness for binding, chafing, cuts, or deformities. If no damage is found, reinstall harness and connectors. Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS harness.

Instrument panel

Refer to the table on the next page.

RS-57

COLLISION DIAGNOSIS Part

Instrument panel

SRS (except the side air bag) is activated

SRS is NOT activated

1. When passenger’s air bag inflates, check the following points for bending, deformities or cracks. ● Opening portion for passenger’s air bag

Check points NRS072 ●

Passenger’s air bag module brackets Back face of instrument panel

Check points NRS079 ●

The portions securing the instrument panel

Check points NRS073

2. If no damage is found, reinstall the instrument panel. 3. If damaged—REPLACE the instrument panel with bolts.

RS-58

COLLISION DIAGNOSIS FOR SIDE COLLISION To repair the SRS for a side collision, perform the following steps. When the built-in type front side air bag is activated in the side collision: 1 Replace the following components: p − All parts of front seat back (including front seat back frame) with side air bag modules (on the side on which side air bag is activated) − Diagnosis sensor unit − Satellite sensor (on the side on which side air bag is activated) 2 Check the SRS components and the related parts using the table shown below. p ● Replace the SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 3 Conduct self-diagnosis using CONSULT-II, or “AIR BAG” warning lamp. Refer to “SRS Operation Check” p for details (RS-37). Ensure entire SRS operates properly. When SRS is not activated in the side collision: 1 Check the SRS components and the related parts using the table shown below. p ● Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 2 Conduct self-diagnosis using CONSULT-II, or “AIR BAG” warning lamp. Refer to “SRS Operation Check” p for details (RS-37). Ensure entire SRS operates properly. In the case of the side collision Part

Side air bag is activated

SRS is NOT activated

Built-in type front side air bags module (LH or RH)

REPLACE all parts of seat back with deployed side air bag module.

1. Check for visible sign of damage (dents, tears, deformation) of the seat back on the collision side. 2. If damaged—REPLACE the damaged seat parts with new bolts and remove the side air bag module. 3. Check for visible signs of damage (tears etc.) of the side air bag module. 4. Check harness and connectors for damage, and terminals for deformities. 5. If no damage is found, reinstall the side air bag module with new torx nuts coated with bonding agent. 6. If damaged—REPLACE the side air bag module with new torx nuts coated with bonding agent. Air bag must be deployed before disposing of it.

Satellite sensor (LH or RH)

REPLACE the satellite sensor on the collision side with new nuts. (Repair the center pillar inner, etc. before installing new one if damaged.)

1. Remove the satellite sensor on the collision side. Check harness connectors for damage, terminals for deformities, and harness for binding. 2. Check for visible signs of damage (dents, cracks, deformation) of the satellite sensor. 3. Install the satellite sensor to check fit. 4. If no damage is found, reinstall the satellite sensor with new nuts coated with bonding agent. 5. If damaged—REPLACE the satellite sensor with new nuts coated with bonding agent.

Diagnosis sensor

REPLACE the diagnosis sensor unit with the new bolts.

1. Check case and bracket for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall the diagnosis sensor unit with new special bolts and ground bolt coated with bonding agent. 4. If damaged—REPLACE the diagnosis sensor unit with new special bolts and ground bolt coated with bonding agent.

Seat belt pre-tensioner assembly

1. Check if the seat belt can be extended smoothly. If the seat belt cannot be extended smoothly. − Check for deformities of the center pillar inner. − If the center pillar inner has no damage, REPLACE the seat belt pre-tensioner assembly. 2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover ad connectors for damage, terminals for deformities, and harness for binding. 3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly. 4. If no damage is found, reinstall the seat belt pre-tensioner assembly with new bolts coated with bonding agent. 5. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts coated with bonding agent. The seat belt pre-tensioner assembly must be deployed before disposing of it.

RS-59

COLLISION DIAGNOSIS

Part

Side air bag is activated

SRS is NOT activated

Seat with built-in type front side air bag

REPLACE all parts of seat back (including seat back frame)

1. Visually check the seat on the collision side. 2. Remove the seat on the collision side and check the following for damage and deformities. ● Harness, connectors and terminals ● Frame and recliner (for front seat), and also adjuster and slides (for front seat) 3. If no damage is found, reinstall the seat. 4. If damaged—REPLACE the damaged seat parts with new bolts.

Center pillar inner

1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation). 2. If damaged—REPAIR the center pillar inner.

Trim

1. Check for visible signs of damage (dents, racks, deformation) of the interior trim on the collision side. 2. If damaged—REPLACE the damaged trim parts.

RS-60

BODY & TRIM SECTION

BT

CONTENTS PRECAUTIONS ............................................................. 2 Service Notice............................................................ 2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 2 GENERAL SERVICING ................................................. 3 Clip and Fastener ...................................................... 3 BODY END .................................................................... 5 Body Front End.......................................................... 5 Body Rear End and Opener...................................... 7 DOOR........................................................................... 13 Front Door................................................................ 13 Rear Door ................................................................ 14 INSTRUMENT PANEL................................................. 15 INTERIOR TRIM .......................................................... 18 Side and Floor Trim ................................................. 18 Door Trim ................................................................. 24 Roof Trim ................................................................. 25 Trunk Room Trim ..................................................... 28 Luggage Room Trim ................................................ 29

Back Door Trim........................................................ 30 EXTERIOR ................................................................... 31 SEAT ............................................................................ 40 Front Seat ................................................................ 40 Heated Seat............................................................. 42 Rear Seat................................................................. 43 SUNROOF.................................................................... 46 Trouble Diagnoses................................................... 49 WINDSHIELD AND WINDOWS .................................. 53 Windshield and Rear Window ................................. 54 Side Window............................................................ 55 Back Door Window .................................................. 56 MIRROR ....................................................................... 58 Door Mirror............................................................... 58 Rearview Mirror ....................................................... 59 BODY ALIGNMENT..................................................... 60 Engine Compartment............................................... 60 Underbody ............................................................... 62

BT

PRECAUTIONS Service Notice ● ● ● ● ●

When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil or damage them. Apply sealing compound where necessary when installing parts. When applying sealing compound, be careful that the sealing compound does not protrude from parts. When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust prevention measures.

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of the Service Manual. If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness, warning lamp (which is one of components of air bags for a frontal collision). WARNING: ● To avoid rendering the SRS inoperative (which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation) all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to do so in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before the harness connectors or for the complete harness) for easy identification.

BT-2

GENERAL SERVICING Clip and Fastener ● ●

Clips and fasteners in BT section correspond to the following numbers and symbols. Replace any clips and/or fasteners which are damaged during removal or installation. Symbol No.

Shapes

Removal & Installation Removal: Remove by bending up with flat-bladed screwdrivers or clip remover.

C101

SBF367BA

SBF302H

C103

Removal: Remove with a clip remover.

SBT095

SBF423H

Push

Push center pin to catching position. (Do not remove center pin by hitting it.)

C203 Push

Installation: SBF708E

SBF258G Removal:

Screwdriver C205

Clip Finisher

MBT080A

BT-3

SBF638C

GENERAL SERVICING Clip and Fastener (Cont’d) Symbol No.

Shapes

Removal & Installation Removal: Remove by bending up with a flat-bladed screwdriver or pliers.

CE117

SBF175DA

SBF174D Removal:

Flat-bladed screwdriver

Clip-A

Finisher

CF118 Clip-B (Grommet)

Body panel

Sealing washer

Clip-B (Grommet) Clip-A Sealing washers

SBF151D

SBF259G Removal: Holder portion of clip must be spread out to remove rod

CR103

SBF770B

SBF768B Removal: 1. Screw out with a Phillips screwdriver. 2. Remove female portion with flat-bladed screw-driver.

CS101

SBF078B

BT-4

SBF992G

BODY END Body Front End ● ● ● ● ●

When removing or installing hood, place a cloth or other padding on the front fender panels and cowl top. This prevents vehicle body from being scratched. Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. Hood adjustment: Adjust at hinge portion. Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood locks engaging mechanism. Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.

REMOVAL — Front bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p 7 p

Remove clips C205 securing bumper fascia to engine undercover. Remove screws and clips C205 securing left and right sides of front fender protector. Remove screws securing radiator core support to bumper fascia. Remove screws securing left and right front fenders to bumper fascia. Remove clips CS101 securing retainer to bumper fascia. Extract bumper fascia assembly. Remove screws securing fog lamps. Then remove fog lamps.

10.8 - 14.6 N·m (1.1 - 1.5 kg-m, 8.0 - 10.8 ft-lb)

YBT001

BT-5

BODY END Body Front End (Cont’d) SEC. 261⋅620⋅623⋅650⋅656 Hood lock adjustment ● Adjust hood so that hood primary lock meshes at a position 1 to 1.5 mm (0.039 to 0.059 in) lower than fender. ● After hood lock adjustment, adjust bumper rubber. ● When securing hood lock, ensure it does not tilt. Striker must be positioned at the center of hood primary lock. ● After adjustment, ensure that hood primary and secondary lock operate properly. .

Hood adjustment

Hood lock secondary latch hooking length More than 5.0 mm (0.197 in) Hood

Secondary latch Bumper rubber adjustment ● Adjust so that hood is aligned

with fender. At that time deflection is approx. 2 mm (0.08 in). [Bumper rubber free height is approx. 13 mm (0.51 in).]

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

C205

★

CS101

C205 ★

Fog lamp

★ Bumper fascia assembly

★

★ ★

: Bumper assembly mounting bolts, screw & clips : N·m (kg-m, ft-lb) NBT033

BT-6

BODY END Body Rear End and Opener 4-DOOR SEDAN When removing or installing trunk lid, place a cloth or other padding on rear fender panels. This prevents vehicle body from being scratched. ● Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. ● Trunk lid adjustment: Adjust at hinge-trunk lid portion for proper trunk lid fit. ● Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment, check trunk lid lock operation. WARNING: ● Be careful not to scratch trunk lid stay when installing trunk lid. A scratched stay may cause gas leakage. ● The contents of the trunk lid stay are under pressure. Do not take apart puncture, apply heat or allow fire near it. ● Opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that trunk lid and fuel filler lid open smoothly. ●

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

.

.

Actuator

Trunk lid lock key cylinder Trunk lid lock

.

Upper Spring holder

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

Opener handle

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

Opener cable Lock nut

Lower

Fuel filler lid opener & control

Trunk lid striker

.

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) Cloth

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) NBT034

BT-7

BODY END Body Rear End and Opener (Cont’d) REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p

Remove license plate lamp. Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips CS101 securing bumper fascia to real panel. Remove clips C205 securing bumper fascia to rear panel upper. Extract bumper fascia assembly.

YBT062

BT-8

BODY END Body Rear End and Opener (Cont’d) 5-DOOR HATCHBACK Back door adjustment: Adjust at hinge-body portion for proper back door fit. Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. WARNING: ● Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas leakage. ● The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or allow fire near it. ● Opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that back door and fuel filler lid open smoothly. ● ●

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5)

Opener handle

Opener cable Lock nut

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

Fuel filler lid opener & control

.

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) Actuator

Key cylinder

Cloth 20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5) : N·m (kg-m, ft-lb)

REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p 6 p

Remove license plate lamp Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips CS101 securing bumper fascia to rear panel. Remove clips C205 securing bumper fascia to rear panel upper. Extract bumper fascia assembly.

BT-9

NBT036

BODY END Body Rear End and Opener (Cont’d)

YBT061

BT-10

BODY END Body Rear End and Opener (Cont’d) WAGON Back door adjustment: Adjust at hinge-body portion for proper back door fit. Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. WARNING: ● Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas leakage. ● The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or allow fire near it. ● Fuel filler lid opener cable: Do not attempt to bend cable using excessive force. ● After installation, make sure that back door and fuel filler lid open smoothly. ● ●

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

.

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

20.6 - 26.5 (2.10 - 2.70, 15.2 - 19.5)

Opener handle Lock nut

Opener cable

.

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

Fuel filler lid opener & control

.

2.9 - 3.8 N·m (0.30 - 0.39 kg-m, 25.7 - 33.6 in-lb)

.

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

Key cylinder

Actuator .

12.7 - 15.7 (1.30 - 1.60, 9.4 - 11.6)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

NBF270

REMOVAL — Rear bumper assembly 1 p 2 p 3 p 4 p 5 p

Remove clips C203 securing left and right chipping protector. Remove screws securing bumper fascia to left and right rear fenders. Remove clips C205 (small) securing bumper fascia to rear panel. Remove clips C205 (large) securing bumper fascia to rear panel upper. Extract bumper fascia assembly.

BT-11

BODY END Body Rear End and Opener (Cont’d) Back door lock control Back door lock adjustment

Back door stay installation

Back door hinge adjustment

Opener handle Fuel filler lid control

Rear fender cover

Back door striker adjustment

Bumper fascia assembly

* : Bumper assembly mounting clips and screws. NBF271

BT-12

DOOR Front Door ● ●

For removal of door trim, refer to “Door Trim” in “INTERIOR TRIM” for details, BT-24. After adjusting door or door lock, check door lock operation. SEC. 800⋅803⋅805

2.93 - 3.82 (0.30 - 0.39, 25.9 - 33.8) Door-hinge adjustment

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6) 6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)

Door-hinge adjustment

6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)

Striker adjustment 13 - 16 (1.3 - 1.6, 9 - 12)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

: Apply grease

NBT038

BT-13

DOOR Rear Door SEC. 820⋅823⋅825 1.47- 1.86 (0.15 - 0.19, 13.0 - 16.5)

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4) 6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6) Door-hinge adjustment 20.6 - 26.5 (2.1 - 2.7, 15 - 20)

5.1 - 6.37 (0.52 - 0.65, 45.1 - 56.4)

5.1 - 6.37 (0.52 -0.65, 45.1 - 56.4)

6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)

6.08 - 7.75 (0.62 - 0.79, 53.8 - 68.6)

Door-hinge adjustment

Striker adjustment

13 - 16 (1.3 - 1.6, 9 - 12)

20.6 - 26.5 (2.1 - 2.7, 15 - 20)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Apply grease

NBT039

BT-14

INSTRUMENT PANEL CAUTION: ● Disconnect both battery cables in advance. ● Disconnect air bag system line in advance. ● Never tamper with or force air bag lid open, as this may adversely affect air bag performance. ● Be careful not to scratch pad and other parts.

REMOVAL — Instrument panel assembly Instrument panel assembly

Combination meter

Remove air bag module (driver’s) and steering wheel. Refer to “SUPPLEMENTAL RESTRAINT SYSTEM” in RS section for details.

p1

Steering column cover and combination switch ● Remove screws.

p2

Instrument lower panel on driver side ● Remove screws.

p3

Cluster lid A ● Remove screws.

p4

Combination meter ● Remove screws and disconnect harness connectors.

p5

Audio

p6

Center ventilator ● Remove screws. ● Pull out with a miniature flat-bladed screwdriver.

p7

A/C or heated control ● Remove screws.

p8

Audio bracket

p9

Glove box assembly ● Remove glove box pin. ● Then disconnect passenger air bag module connector.

10 p

11 p

12 p 13 p

14 p

15 p

16 p

17 p

Passenger air bag module ● Refer to “SUPPLEMENTAL RESTRAINT SYSTEM” in RS section for details.

Lower cover ● Remove clip

AT finisher or MT shift lever boot

Rear console box ● Remove console mask and screws.

Front console box ● Remove screws and bolts.

Front defroster grill ● Disconnect harness connector.

Front pillar garnish ● Refer to “Side and Floor Trim” in “INTERIOR TRIM” for details, BT-18.

Instrument panel and pads ● Remove nuts and bolts. ● Remove door mirror switch and disconnect the connector.

BT-15

Audio & A/C control

Console box

INSTRUMENT PANEL SEC. 248⋅251⋅272⋅487⋅680⋅685⋅969

2.8 - 4.8 (0.29 - 0.49, 24.8 - 42.5)

★

★

★ ★

★ 14.7 - 24.5 (1.50 - 2.5, 10.8 - 18.1)

★

Metal clip Metal clip Metal clip

Metal clip Metal clip

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) ★ : Instrument panel assembly mounting bolts & nuts. NBT040

BT-16

INSTRUMENT PANEL

Hook .

Cloth

.

Pull

Metal clip

Bracket Metal clip

Metal clip

Bolt Metal clip

NBT041

BT-17

INTERIOR TRIM Side and Floor Trim CAUTION: Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.

REMOVAL — Body side trim 4-door sedan 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p 12 p 13 p

Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove rear pillar garnishes. High-mount stop lamp. Remove rear parcel shelf finisher. Remove welt. Remove seatback finisher.

SEC. 678⋅749⋅769⋅799 Metal clip Metal clip Metal clip

Metal clip

Metal clip

Metal clip

X: Metal clips YBT011

BT-18

INTERIOR TRIM Side and Floor Trim (Cont’d)

Metal clip

Metal clip

üüMetal clip

Garnish

Metal clip

Metal clip Metal clip

Metal clip

Metal clip

YBT012

BT-19

INTERIOR TRIM Side and Floor Trim (Cont’d) REMOVAL — Body side trim 5-door hatchback ●

p 2 p 3 p 4 p 5 p 6 p 7 p 1

8 p 9 p 10 p 11 p 12 p 13 p

Remove parcel shelf before removing body side trim. Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove rear parcel shelf side finishers. Remove rear pillar finishers. Remove luggage room rear plate. Remove luggage room rear finisher. Remove luggage room side lower finishers.

SEC. 678⋅749⋅769⋅799

Metal clips Metal clip Metal clip Metal clip

Metal clip

Metal clip Metal clip

Metal clip

Metal clip

Metal clip

X : Metal clips NBT042

BT-20

INTERIOR TRIM Side and Floor Trim (Cont’d)

Metal clip

Metal clip Metal clip

Garnish

Metal clip

Metal clip Metal clip

Metal clip Metal clip

Metal clip

Metal clip Metal clip

Metal clip

YBT014

BT-21

INTERIOR TRIM Side and Floor Trim (Cont’d) REMOVAL — Body side trim Wagon ●

p 2 p 3 p 4 p 5 p 6 p 7 p 1

8 p 9 p 10 p 11 p 12 p 13 p

Remove parcel shelf before removing body side trim. Remove front and rear seats. Refer to “SEAT” for details, BT-40. Remove front and rear kicking plates. Remove dash side lower finishers. Remove front and rear body side welts. Remove front pillar garnishes. Remove center pillar lower garnishes. Remove front seat belt shoulder adjustment anchor bolt covers and anchor bolts (Refer to “SEAT BELTS” in RS section for anchor bolt details). Remove center pillar upper garnishes. Remove luggage room side center finisher. Remove luggage room side upper finisher. Remove luggage room rear plate. Remove luggage room rear finisher. Remove luggage room side lower finisher.

Metal clip Metal clips Metal clip

.

Clip Metal clip

Metal clip

Clip Metal clip Guard net hook

Metal clip

: Metal clips NBF273

BT-22

INTERIOR TRIM Side and Floor Trim (Cont’d) Metal clip Metal clip

Metal clip

Garnish

Metal clip

Metal clip Metal clip

12.7 - 15.7 N·m (1.30 - 1.60 kg-m, 9.4 - 11.6 ft-lb)

Metal clip Metal clip

Metal clip

NBF272

BT-23

INTERIOR TRIM Door Trim REMOVAL — Door trim 1 p 2 p 3 p 4 p 5 p

Remove pull handle. Remove power window switch assembly and disconnect the connector (Power window models). Remove window regulator handle (Manual window models). Remove bolts, screws and clips C101 securing door finisher. Lift out door finisher.

SEC. 251⋅267⋅809⋅828

clips

Manual window regulator handle Hook

Removal Push Flat-bladed screwdriver

Metal clip Squeeze the regulator handle clip in place with a screwdriver and remove the regulator handle from the regulator shaft. Set the regulator handle clip as shown in figure p 1 . Installation

Front

Push the regulator handle to install it into the regulator shaft. Install the regulator handle in place as shown in the figure with the window completely closed.

YBT015

BT-24

INTERIOR TRIM Roof Trim REMOVAL — Headlining 4-door sedan 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p

Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove

front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-18. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp assembly. assist grips. clips C103 securing headlining. headlining.

SEC. 264⋅738⋅963⋅964

C103 Manual type

NBT043

BT-25

INTERIOR TRIM Roof Trim (Cont’d) REMOVAL — Headlining 5-door hatchback 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p

Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove

front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-20. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp assembly. assist grips. roof rear garnish. headlining.

SEC. 264⋅738⋅963⋅964

Manual type Metal clip

Metal clip

NBT044

BT-26

INTERIOR TRIM Roof Trim (Cont’d) REMOVAL — Headlining Wagon 1 p 2 p 3 p 4 p 5 p 6 p 7 p 8 p 9 p 10 p 11 p 12 p 13 p 14 p

Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove

front and rear seats. Refer to “SEAT” for details, BT-40. front and rear seat belts. Refer to “SEAT BELTS” in RS section for details. body side trim. Refer to “Side and Floor Trim” for details, BT-22. sunroof switch. (Models equipped with electric sunroof) handle and lamp cover. (Models equipped with manual sunroof) sunroof welt. (Models equipped with sunroof) sun visors. interior lamp (center) and interior lamp (rear). assist grips. clips C103 . luggage net escutcheons. roof rear garnish. speakers. headlining.

9 p

C103

Manual type Metal clip

Metal clip

NBT045

BT-27

INTERIOR TRIM Trunk Room Trim SEC. 849

Metal clip

Front

Metal clip

YBT018

BT-28

INTERIOR TRIM Luggage Room Trim

NBF275

BT-29

INTERIOR TRIM Back Door Trim REMOVAL — Back door trim 1 p 2 p 3 p 4 p

Remove Remove Remove Remove

back door lower finisher. back door upper finisher. back door side finisher. high-mounted stop lamp.

Metal clip

Metal clip

Metal clip 2.9 - 3.8 N·m (0.30 - 0.39 kg-m, 26.0 - 33.9 in-lb)

Metal clip

Metal clip

Metal clip

Metal clip

NBT054

BT-30

EXTERIOR

NBT051

BT-31

EXTERIOR

NBT052

BT-32

EXTERIOR 1 p 2 p

6 p

Hood front sealing rubber

Windshield upper molding

SEC. 720

SEC. 650 Hood front sealing rubber

Radiator core support sealing rubber

1. Cut off sealant at glass end. 2. Clean the side on which panel was mounted. 3. Set molding fastener and apply primer to body panel, and apply sealant to body.

Molding Clip

YBT020

3 p 4 p

Fastener

Cowl top seal and cowl top grille Glass

SEC. 660

Double-faced adhesive tape

Cowl top seal

Apply primer

Dam rubber

Apply sealant Sealant

4. Install molding by aligning the molding mark located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner. Cowl top grille

SBF342H

7 p

YBT021

5 p

Drip weatherstrip

Windshield side molding

Mounted with screws.

Drip weatherstrip

Front pillar

Drip weatherstrip

Body panel

Upper

Front

SEC. 720

Screw Windshield side molding YBT022

NBT058

BT-33

EXTERIOR 8 p

10 p

Body side welt

Door outside molding

Front door SEC. 800

Screw

Door outer molding Clip Door outer panel

Rear door SEC. 820

Outside SBT043

9 p

Screw

Door weatherstrip

Door outer molding

EC. 800⋅820 Clip

Clip

Clip

Door panel

11 p

SBT067

Sunroof lid weatherstrip

SEC. 736 Roof panel Clip

Clip

Glass lid

YBT024

Sunroof lid weatherstrip Sunroof rail assembly Front YBT025

BT-34

EXTERIOR 12 p

14 p

Side guard molding

Rear window lower molding

SEC. 766 Rear window glass

Rear window lower molding

Locating pins

Removal: Remove molding by cutting around its perimeter. Installation: Refer to “Rear window”. YBT027

15 p

Trunk lid weatherstrip

SEC. 843 Marking at vehicle center : Double-faced adhesive tape Vehicle center

Heat gun YBT026

●

p 13

With a vehicle coated with Hard Clear Coat, use double-faced 3M adhesive tape Product No. 5572 or equivalent, after priming with 3M primer Product No. N-200 or C-100 or equivalent.

Bonding portion

16 p

SBT069

Back door window molding

5-door hatchback Back door molding

Back door molding

Rear window upper molding

Basically the same as windshield upper molding. Refer to p 6 Windshield upper molding.

Glass

Glass Double side adhesive tape Back door molding

300 (11.81)

60 (2.36)

Glass Back door molding

Back door molding Unit: mm (in) Glass YBT050

Wagon See “Back door window”. Refer to BT-57.

BT-35

EXTERIOR 17 p

Back door weatherstrip

Wagon

Vehicle center

Bonding point

NBF278

5-door hatchback

Vehicle center

Bonding portion YBT056

BT-36

EXTERIOR 18 p ● ●

Rear combination lamp Rear combination lamps are installed with nuts and butyl sealant. When removing inside rear combination lamp (installed on back door), first remove “Back door finisher”. Refer to p 22 Back door finisher.

SEC. 265 Heat gun Heat gun

Heat gun

Butyl seal

Heat gun ● Apply butyl seal evenly as it tends to become thin in

the corners. ● Warm up lamp assembly area to a temperature of a

Butyl seal

little below 60°C (140°F). NBT056

19 p

Center mud guard

SEC. 767

CF118

C205

Double-faced adhesive tape

NBT046

BT-37

EXTERIOR 20 p

Front hood grille

Hook Hook

Hook

NBT047

21 p

Roof rail

Roof rail 5.1 - 6.4 N·m (0.52 - 0.65 kg-m, 45.1 - 56.6 in-lb)

Clip

Pawl Hook

Front

Center

Clip Hook

Rear NBF280

BT-38

EXTERIOR 22 p

Back door finisher

Nut x 8

NBF279

BT-39

SEAT When removing or installing seats with side air bag module, be sure to disconnect or connect side air bag sub harness connector. ● When removing or installing the seat trim, handle it carefully to keep dirt out and avoid damage. ★ For Wiring Diagram, refer to “POWER SEAT” in EL section. ●

Front Seat Manual seat

18 - 24 (1.9 - 2.4, 14 - 17)

18 - 24 (1.9 - 2.4, 14 - 17)

Side airbag sub harness connector

21 - 26 (2.1 - 2.7, 15.5 - 19.2)

18 - 24 (1.9 - 2.4, 14 - 17)

: N·m (kg-m, ft-lb)

BT-40

NBT048

SEAT Front Seat (Cont’d) Power Seat

18 - 24 (1.9 - 2.4, 14 - 17)

21 - 26 (2.1 - 2.7, 15.5 - 19.2)

Side airbag sub harness connector

18 - 24 (1.9 - 2.4, 14 - 17)

18 - 24 (1.9 - 2.4, 14 - 17) : N·m (kg-m, ft-lb) NBF266

BT-41

SEAT Heated Seat ● ● ●

When handling seat, be extremely careful not to scratch heating unit. To replace heating unit, seat trim and pad should be separated. Do not use any organic solvent, such as thinner, benzene, alcohol, gasoline, etc. to clean trims.

Seatback heating unit removal & installation Seatback trim

Heating unit

Thermostat

Trim temperature °C (°F)

Increasing to 35 - 45 (95 - 113)

Decreasing to 15 - 25 (59 - 77)

Thermostat operation

OFF

ON

Seat cushion trim SBF424H

★ For Wiring Diagram, refer to “HEATED SEAT” in EL section.

BT-42

SEAT ●

When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.

Rear Seat

Rear seat back hinge (center) & hook

Rear seat back striker (RH)

Rear seat back hinge (LH)

Rear seat hook

.

43.1 - 54.9 (4.4 - 5.6, 31.8 - 40.5)

20.6 - 26.5 (2.1 - 2.7, 15.2 - 19.5)

12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)

.

23.0 - 28.0 (2.4 - 2.9, 16.9 - 20.6)

Rear seat back hinge (center)

Suitable tool

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb) NBF285

BT-43

SEAT Rear Seat (Cont’d) Type 1 SEC. 880

Rear seat hinge

12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6) Rear seat hook : N·m (kg-m, ft-lb) YBT054

BT-44

SEAT Rear Seat (Cont’d) Type 2 SEC. 880

Rear seat back striker (LH) Rear seat back striker (RH)

Rear seat side back hinge

Rear seat back hinge

Rear seat hinge

Rear seat hook

12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)

12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)

5.1 - 6.47 (0.52 - 0.66, 45.1 - 57.3)

43.1 - 54.8 (4.4 - 5.5, 32 - 40)

Tightening sequence A: Finger B tight B: 43.1 - 54.8 (4.4 - 5.5, 32 - 40) C: 43.1 - 54.8 (4.4 - 5.5, 32 - 40)

43.1 - 54.8 (4.4 - 5.5, 32 - 40)

A, C

.

12.7 - 15.7 (1.3 - 1.6, 9.4 - 11.6)

: N·m (kg-m, ft-lb) : N·m (kg-m, in-lb)

NBT057

BT-45

SUNROOF ADJUSTMENT Install motor & limit SW assembly and sunroof rail assembly in the following sequence: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Arrange equal lengths of link and wire assemblies on both sides of sunroof opening. Connect sunroof connector to sunroof switch and positive (+) power supply. Set lid assembly to fully closed position by operating open/tilt sunroof switch. Fit outer side of lid assembly to the surface of roof on body outer panel. Remove motor, and keep sunroof switch pressed to rear side until motor pinion gear reaches the end of its rotating range. Install motor. Check that motor drive gear fits properly in wires. Press front side of sunroof switch to check lid assembly for normal tilting. Check sunroof lid assembly for normal operations (tilt-up, tilt-down, open, and close). Front

Rear Lid assembly

Tilting up & down range

Outer body panel Closing & opening range

Closing & opening range SBF920F

BT-46

SUNROOF REMOVAL After any adjustment, check sunroof operation and lid alignment. Handle finisher plate and glass lid with care so not to cause damage. ● It is desirable for easy installation to mark each point before removal. CAUTION: Always work with a helper. ● ●

Link and wire assembly

Sunroof frame assembly

Shade assembly

Tilt glass lid up. 1 p

Sunroof lid mount screws

2 p

Lid assembly

3 p

Rear drain mount screws

4 p

Rear drain assembly

Operate sunroof switch to tilt glass lid down. 5 p

Shade assembly

Sunroof switch/interior accessories/headlining (Models equipped with sunroof) ● Refer to “Roof Trim” in “INTERIOR TRIM” for details, BT-25, BT-26, BT-27. 6 p

Motor switch bracket

7 p

Motor assembly

8 p

Wind deflector mount nuts

9 p

Wind deflector mount screws

10 p

Wind deflector assembly

11 p

Drain hoses

12 p

Sunroof unit bracket

13 p

Sunroof frame assembly

14 p

Guide stopper

15 p

Link and wire assembly

BT-47

Lid assembly

Motor assembly

SUNROOF ★ For Wiring Diagram, refer to “ELECTRIC SUNROOF” in EL section. SEC. 736 Screw

Lid assembly

Guide stopper

Rear drain screw

Rear drain assembly Shade assembly

Link and wire assembly

Guide stopper Wind deflector mounting screws Wind deflector assembly

Wind deflector mounting nuts

Sunroof frame assembly

Drain hose

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.4)

Motor assembly Sunroof unit bracket Motor switch bracket

Manual type

5.1 - 6.4 (0.52 - 0.65, 45.1 - 56.4)

Drive Handle

: N·m (kg-m, in-lb) : Apply grease NBT049

BT-48

SUNROOF Using flat-bladed screwdriver, pry shade assembly holder off rail. Then pull shade assembly forward to remove it from rail.

Holder

Front Shade holder

Shade ASSY

Rail

YBT060

Trouble Diagnoses DIAGNOSTIC TABLE NOTE: For diagnosing electric problem, refer to “ELECTRIC SUNROOF” in EL section. Check item (Components) Wind deflector

Adjustment

Drain hoses

Weatherstrip

Link and wire assembly

Reference page

BT-49

BT-50

BT-51

BT-51

BT-52

Excessive wind noise

1

2

3

Water leaks

1

2

3

Sunroof rattles

1

4

2

3

Excessive operation noise

1

2

3

Symptom

The numbers in this table mean checking order.

WIND DEFLECTOR Roof panel

1. Open lid 2. Check visually for proper installation. 3. Check to ensure a proper amount of petroleum jelly has been applied to wind deflector connection points; apply if necessary.

Wind reflector arm Wind reflector SBT331

Roof panel

4. Check that wind deflector is properly retracted by hand. If it is not, remove and visually check condition. (Refer to removal procedures, BT-47). If wind deflector is damage, replace with new one. If wind deflector is not damage, re-install properly.

Wind reflector arm Wind reflector

SBT332

BT-49

SUNROOF Trouble Diagnoses (Cont’d) ADJUSTMENT If any gap or height differences between lid and roof is found, check lid and adjust as follows: SEC. 736

5.4 - 6.3 (0.213 - 0.248) Roof panel

0.7 ± 0.028 ± 0.039

Lid

33.1 ± 5 (1.303 ± 0.197) Roof panel

12+1.2 -2.0 (0.47+0.047 -0.079 )

Lid

Unit: mm (in)

SBT381

Gap Adjustment 1. Remove shade assembly. (Refer to removal procedures BT-47, for details). 2. Tilt lid up. 3. Loosen lid securing nuts (3 each on left and right sides), then tilt lid down. 4. Adjust lid from outside of vehicle so it resembles “A-A” as shown in the figure above. 5. Tilt lid up and down until it is adjusted to “B-B” as shown in the figure above. 6. After adjusting lid, tilt lid up and tighten nuts. 7. Tilt lid up and down several times to check that it moves smoothly.

Height difference adjustment 1. Tilt lid up and down. 2. Check height difference between roof panel and lid to see if it is as “A-A” as shown in the figure above. 3. If necessary, adjust it by using one of following procedures: ● Adjust by adding or removing adjustments shim(s) between lid and link assembly. ● If lid protrudes above roof panel, add shim(s) or plain washer(s) at sunroof mounting bracket or stud bolt locations to adjust sunroof installation as required.

BT-50

SUNROOF Trouble Diagnoses (Cont’d) DRAIN HOSES

Drain hose

SBT335

1. Remove headlining to access drain hose connections. (Refer to “REMOVAL — Headlining” in “INTERIOR TRIM”, BT-25, BT-26, BT-27 for detail). 2. Check visually for proper connections, damage or deterioration. (The figure shows only the front side.) Sunroof frame assembly

Drain hose SBT333

.

3. If leakage occur around trunk room, remove trunk room side trim and check connecting area. Check for proper connection, damage or tear. 4. Pour water into drain hoses and find damaged portion. ● If any damaged portion is found at each step, replace the damaged part.

Sunroof drain hose Front

Grommet

Rear wheel house inner LH

Rear fender inner LH SBT334

WEATHERSTRIP In the case of leakage around lid, close lid and pour water over lid to find damaged or gap portion. 1. Remove lid assembly. (Refer to removal procedures, BT-47, for details). 2. Visually check weatherstrip for proper installation. If a gap exists between lid and weatherstrip, check for sufficient amount of butyl seal. If required, remove weatherstrip and apply butyl seal. Refer to “EXTERIOR” BT-31 for details. ●

BT-51

SUNROOF Trouble Diagnoses (Cont’d) 3. Check weatherstrip visually for damage, deterioration, or flattening. ● If any damage is found, replace weatherstrip. CAUTION: Do not remove weatherstrip except when replacing, or filling up butyl seal.

LINK AND WIRE ASSEMBLY Before replacing a suspect part, carefully ensure it is the source of noise being experienced. 1. Check link to determine if coating film has been peeled of to such an extent that substrate is visible. Check also to determine if link is the source of noise. If it is, replace it. 2. Visually check to determine if a sufficient amount of petroleum jelly has been applied to wire or rail groove. If not, add petroleum jelly as required. 3. Check wire for any damage or deterioration. If any damage is found, remove rear guide (refer to removal procedures, BT-47 for details), then replace wire.

BT-52

WINDSHIELD AND WINDOWS REMOVAL

Cutting sealant

After removing moldings, remove glass using piano wire or power cutting tool and inflatable pump bag. WARNING: ● Be careful not to scratch the glass when removing. ● Do not set or stand the glass on its edges. Small chips may develop into cracks.

Glass

SBF034B

INSTALLATION Use a genuine Nissan Urethane Adhesive Kit or equivalent and follow the instructions furnished with it. ● While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by passenger compartment air pressure when a door is closed. ● The molding must be installed securely so that it is in position and leaves no gap. ● Inform the customer that the vehicle should remain stationary until urethane adhesive has completed cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: ● Keep heat and open flames away as primers and adhesive are flameable. ● The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. ● Use in an open , well ventilated location. Avoid breathing the vapors. They can be harmful if inhaled. If affected by vapor inhalation, immediately move to an area with fresh air. ● Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield in case of an accident. CAUTION ● Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to expiration or manufacture date printed on the box. ● Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator. ● Do not leave primers and adhesive cartridge unattended with their caps open or off. ● The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing times varies depending on temperature and humidities. The curing time will increase under higher temperatures lower humidities. ●

Windshield glass

Interior auto glass cut-out knife kit

Windshield glass

SBT472 Inflatable pump bag

SBT473

BT-53

WINDSHIELD AND WINDOWS Windshield and Rear Window Glass side

Body side Windshield Install spacer to panel

Install dam rubber. Windshield and rear window

Cowl top Glass

8 (0.31)

8 (0.31)

8 (0.31)

Spacer

joint portion

455.4 mm (17.93 in)

Apply sealant evenly 12 - 15 (0.47 - 0.59)

YBT033

Install molding fastener. When installing it, heat body panel and fastener to approx. 30 to 40°C (86 to 104°F). Windshield

Vehicle center

Upper & side molding fasteners Fastener

Unit: mm (in)

Rear window

7 - 8 (0.28 - 0.31) Dam rubber

Glass

YBT034

Panel

Double-faced adhesive tape SBF017A

REPAIRING WATER LEAKS FOR WINDSHIELD Leaks can be repaired without removing and reinstalling glass. If water is leaking between caulking material and body or glass, determine the extent of leakage. This can be determined by applying water while pushing glass outward. To stop the leak, apply primer (if necessary) and then sealant to the leak point.

BT-54

WINDSHIELD AND WINDOWS Side Window Primer portion Glass side

Body side

.

Window glass A

A A

A

B B

B Primer portion

B

Primer portion

B-B

A-A

Primer portion

Primer portion Primer portion B-B

A-A Primer portion

Glass

Glass

NBF283

Sealing portion and installation

Clip (bonded on glass)

C-C

Glass

D D Clip (bonded on glass)

Glass

A

D-D

A

More than 7 (0.28) More than 8 (0.32)

More than 8 (0.32)

More than 7 (0.28)

B B

Glass Glass

Molding Apply sealant evenly

BT-55

Unit: mm (in) NBF281

WINDSHIELD AND WINDOWS Back Door Window Construction and removal/reinstallation method of back door window are basically the same as those of windshield. 5-door hatchback ● For details of moldings, refer to “EXTERIOR”, BT-31. ●

Dam rubber portion (Glass side)

Primer portion (Glass side)

Primer Back door molding

Back door molding

Back door molding Primer

Dam rubber

Back door molding

Primer

Sealant portion (Body side)

400 (15.75)

28 (1.10) 41 (1.61) 33 (1.30)

Primer 33 (1.30) Primer portion (Body side)

18.4 (0.724)

41.2 (1.622)

Primer

33 (1.30) 30 (1.18)

8.75 (0.3445) Sealant quantity Primer

12 - 15 (0.47 - 0.59) 7-8 (0.28 - 0.31)

Unit: mm (in)

YBT035

BT-56

WINDSHIELD AND WINDOWS Back Door Window (Cont’d) Wagon

4.5 (0.2)

2 (0.1)

7 (0.28)

Sealant 12 (0.47) Back door molding Glass Glass side Glass

Body side 16 (0.6)

17 (0.7)

Pin Back door molding

.

Glass A-A

Primer portion

B-B

C-C

Primer portion

Unit: mm (in) NBT055

BT-57

MIRROR Door Mirror CAUTION: Be careful not to scratch door rearview mirror body. ★ For Wiring Diagram, refer to “POWER DOOR MIRROR” in EL section.

REMOVAL — Door mirror 1 p 2 p 3 p 4 p

Remove door trim. Refer to “Door Trim” for details, BT-24. Remove inner cover from front corner of door. Disconnect door mirror harness connector. Remove bolts securing door mirror, then remove door mirror assembly.

SEC. 963

Pawl

Removal: ● Wrap flat-blade of screwdriver with a cloth to prevent scratching. Do not insert too far. Push mirror away from car to release.

Mirror

Inside Cloth

Outside

Flat-bladed screwdriver

YBT036

BT-58

MIRROR Rearview Mirror REMOVAL Remove rearview mirror by pushing deflect spring with screwdriver as shown in the figure.

Windshield

Mirror assembly

Mounting bracket Windshield

Mirror assembly

Mounting bracket

Side view

Mounting bracket location Bracket

NBT059

INSTALLATION

85 - 90 mm (3.34 - 3.54 in)

Center of windshield YBT049

1. Install mounting bracket as follows: (1) Determine mounting bracket position on windshield by measuring from top of windshield to top of mounting bracket as shown in the figure. (2) Mark location on outside of windshield with wax pencil or equivalent. (3) Clean attaching point on inside of windshield with an alcoholsaturated paper towel. (4) Sand bonding surface of mounting bracket with sandpaper (No. 320 or No. 360). (5) Clean bonding surface of mounting bracket with an alcoholsaturated paper towel. (6) Apply Loctite Adhesive 11067-2 or equivalent to bonding surface of mounting bracket. (7) Install mounting bracket at premarked position and press mounting bracket against glass for 30 to 60 seconds. (8) After five minutes, wipe off excess adhesive with an alcoholmoistened paper towel. 2. Install rearview mirror.

BT-59

BODY ALIGNMENT ● ● ● ● ● ●

All dimensions indicated in figures are actual ones. When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken at the center of the mounting holes. An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of “X”, “Y” and “Z”.

Imaginary base line

Vehicle center

“Z”: Imaginary base line [200 mm below datum line (“0Z” at design plan)] Front axle center SBF874GB

Engine Compartment MEASUREMENT

Unit: mm YBT038

BT-60

BODY ALIGNMENT Engine Compartment (Cont’d) MEASUREMENT POINTS Unit: mm

Radiator core support side and Radiator core support

Cowl top

7 dia.

6.2 dia. 7 dia. Front YBT039 .

Front suspension spring support and cowl top side

YBT040

Front side member LH side

Front YBT041

YBT042

Hood lock stay and Radiator core support lower

Front side member RH side

Front .

YBT043

Radiator core support upper center and hood lock stay

YBT045

BT-61

YBT044

BT-62

Unit: mm

Front

Front

All dimension indicated in these figures are actual ones.

RH side

LH side

* This figure is underside view.

Below

Above

Rear

BODY ALIGNMENT Underbody

MEASUREMENT

YBT046

BODY ALIGNMENT Underbody (Cont’d) MEASUREMENT POINTS

Bottom view of vehicle

Rear

14 dia.

12 dia.

18 dia.

16 dia.

16 dia. 12.5 dia.

16 dia. 12.5 dia. LH side

RH side

16 dia.

Front coordinates A , p a p x : 330 y : −650 z : 213 B , p b p x : 495 y : −490 z : 356.6 C , p c p x : 455 y : −35 z : 377.6 D , p d p x : 450 y : 70 z : 254 E , p e p x : 410 y : 310 z : 133.8 F , p f p x : 587 y : 405 z : 169.4 G , p g p x : 393 y : 500 z : 128.6 H , p h p x : 414.5 y : 1,210 z : 124.9

Rear coordinates pJ , pj x : 412.5 y : 1,625 z : 123.2 K , p k p x : 524 y : 2,005 z : 209 L , p l p x : 555 y : 2,085 z : 259 M p

x : 145 y : 2,507 z : 250 N p

x : 300 y : 2,550 z : 402.3 n p

x : −300 y : 2,550 z : 428.3 P p

x : 512 y : 2,900 z : 346.5 p p

x : −544 y : 2,882 z : 347.7 Q p

x : 542 y : 3,385.6 z : 339.4

14 dia.

q p

x : −570.5 y : 3,380 z : 346.5

12 dia. 16 dia. Bolt head

Unit: mm

Bolt head

Front and rear strut tower centers

12 dia.

Coordinates: R , p r p x : 527.3 y : −5.1 z : 780.1 S , p s p x : 478 y : 2,522 z : 527.3

16 dia. 18 dia.

Front p R , p r 88 dia. S , p s 60.8 dia. Rear p

Front YBT047

BT-63

BODY ALIGNMENT NOTE

BT-64

HEATER & AIR CONDITIONER SECTION

HA

CONTENTS PRECAUTIONS AND PREPARATION.......................... 3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″............. 3 Precautions for Working with HFC-134a (R-134a) ... 3 General Refrigerant Precautions ............................... 4 Precautions for Refrigerant Connection .................... 4 Precautions for Servicing Compressor...................... 7 Special Service Tools ................................................ 7 HFC-134a (R-134a) Service Tools and Equipment.................................................................. 8 Precautions for Service Equipment ......................... 10 DESCRIPTION ............................................................. 12 Refrigeration Cycle .................................................. 12 CSV613 Variable Displacement Compressor.......... 14 Component Layout .................................................. 18

HEATER DESCRIPTION ............................................................. 19 Control Operation .................................................... 19 Air Flow.................................................................... 19

AUTO DESCRIPTION ............................................................. 20 Introduction .............................................................. 20 Features................................................................... 20 Control Operation .................................................... 21 Discharge Air Flow................................................... 23

HEATER TROUBLE DIAGNOSES ............................................. 24 Operational Check ................................................... 24

AUTO TROUBLE DIAGNOSES ............................................. 26 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................ 26 Symptom Chart........................................................ 28 Checking Resistor.................................................... 30 Preliminary Check.................................................... 30 Performance Test Diagnoses .................................. 33 A/C Performance Chart ........................................... 35 Trouble Diagnoses for Abnormal Pressure ............. 36 Component Location................................................ 39 Wiring Diagram - HEATER -.................................... 40 Circuit Diagram - Air Conditioner............................. 41 Wiring Diagram - A/C - ............................................ 42 Main Power Supply and Ground Circuit Check ...... 51 Diagnostic Procedure 1 ........................................... 52 Diagnostic Procedure 2: Models with relay type 1.. 54 Diagnostic Procedure 2: Models with relay type 2.. 56 Diagnostic Procedure 3: Models with relay type 1.. 57 Diagnostic Procedure 3: Models with relay type 2.. 59 Diagnostic Procedure 4: Models with relay type 1.. 61 Diagnostic Procedure 4: Models with relay type 2.. 63 Diagnostic Procedure 5 ........................................... 65 Diagnostic Procedure 6 ........................................... 66 Diagnostic Procedure 7 ........................................... 68 Diagnostic Procedure 9 ........................................... 69 Diagnostic Procedure 10 ......................................... 70 Diagnostic Procedure 11 ......................................... 74 Diagnostic Procedure 12 ......................................... 75 Diagnostic Procedure 13 ......................................... 76 Diagnostic Procedure 14 ......................................... 77 Electrical Components Inspection ........................... 78 Control Panel System.............................................. 80

HA

Removal and Installation ......................................... 81 Control Linkage Adjustment..................................... 82 SYSTEM DESCRIPTION ............................................. 84 Overview of Control System.................................... 84 Control System Input Components ......................... 84 Control System Auto Amplifier (Auto amp.)............. 87 Control System Output Components....................... 90 SERVICE PROCEDURES ......................................... 100 HFC-134a (R-134a) Service Procedure ................ 100 Maintenance of Lubricant Quantity in Compressor ........................................................... 102 Refrigerant Lines ................................................... 104

Checking Refrigerant Leaks .................................. 106 Compressor Mounting ........................................... 109 Compressor - Model CR-14 (Calsonic make) ........ 111 Compressor Clutch ................................................. 111 Thermal Protector ...................................................113 CSV613 Compressor..............................................114 Compressor Clutch .................................................114 Ventilation Air Filter.................................................117 SERVICE DATA AND SPECIFICATIONS (SDS) .......118 General Specifications............................................118 Inspection and Adjustment .....................................118

HA-2

PRECAUTIONS AND PREPARATION Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The composition varies according to optional equipment): ● For a frontal collision The Supplemental Restraint System consists of driver’s air bag module (located in the center of the steering wheel), front passenger’s air bag module (located on the instrument panel on passenger’s side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ● For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses covered with yellow insulation or tape either just before the harness connectors or for the complete harness are related to the SRS.

WARNING: ●

● ●

Precautions for Working with HFC-134a (R-134a)

CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor failure is likely to occur. Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor failure is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: a: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. c: Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove R-134a from the A/C system, using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. e: Do not allow lubricant (Nissan A/C System Oil Type S or type R) to come in contact with styrofoam parts. Damage may result.

HA-3

PRECAUTIONS AND PREPARATION General Refrigerant Precautions WARNING: ● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. ● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. ● Do not store or heat refrigerant containers above 52°C (126°F). ● Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. ● Do not intentionally drop, puncture, or incinerate refrigerant containers. ● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. ● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. ● Do not introduce compressed air to any refrigerant container or refrigerant component.

Precautions for Refrigerant Connection A new type refrigerant connection has been introduced to all refrigerant lines except the following location. ● Expansion valve to cooling unit.

FEATURES OF NEW TYPE REFRIGERANT CONNECTION ●

●

The O-ring is relocated in a groove for proper installation. This eliminates the change of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the connecting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. Flange portion

Union-nut portion New

Former

New

Former

Nut

Flange

O-ring

O-ring

O-ring

O-ring Union

O-ring

O-ring

O-ring

O-ring Sealed direction SHA815E

HA-4

PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Cont’d) O-RING AND REFRIGERANT CONNECTION N p

N p

Cooling unit

N p

N p

N p

F p

Compressor Condenser

N p N p

N : New type refrigerant connection p F : Formertype refrigerant connection p

F p

Expansion valve

Liquid tank

l : O-ring size

KHA101

CAUTION: The new and former connections use different O-ring configurations. Do not confuse O-rings since they are interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.

O-ring parts number and specifications Connection type

O-ring size

Part number

D

mm (in)

W

mm (in)

92471 N8210

6.8 (0.268)

1.85 (0.0728)

Former

92470 N8200

6.07 (0.2390)

1.78 (0.0701)

New

9247 N8210

10.9 (0.429)

2.43 (0.0957)

92475 71L00

11.0 (0.433)

2.4 (0.094)

92473 N8210

13.6 (0.535)

2.43 (0.0957)

Former

92475 72L00

14.3 (0.563)

2.3 (0.091)

New

92474 72L00

14.3 (0.563)

2.43 (0.0957)

New 8

12 Former New 16 SHA814E 19

HA-5

PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Cont’d) WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: When replacing or cleaning refrigerant cycle components, observe the following: ● When the compressor is removed, store it in the same position as it is when mounted on the car. Failure to do so will cause lubricant to enter the low pressure chamber. ● When connecting tubes, always use a torque wrench and a back-up wrench. ● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. ● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before connection. ● Allow components stored in cool areas to warm to ambient temperature before removing seal caps. This prevents condensation from forming inside A/C components. ● Thoroughly remove moisture from the refrigeration system before charging the refrigerant. ● Always replace used O-rings. ● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type R for compressor-model CR-14 Part number: KLH00-PAGR0 Lubricant name: Nissan A/C System Oil Type S for compressor-model CSV613 Part number: KLH00-PAGS0 ● O-ring must be closely attached to dented portion of tube. ● When replacing the O-ring, be careful not to damage O-ring and tube. ● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. ● After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. Torque wrench

Apply lubricant

Do not apply lubricant to thread.

OK

NG

O-ring

NG

NG

Inflated portion OK

OK

NG

Plug RHA861F

HA-6

PRECAUTIONS AND PREPARATION Precautions for Servicing Compressor ● ● ● ● ●

●

Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to HA-102. Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner. After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation.

Special Service Tools CR-14 compressor Tool number Tool name

Description

KV99106700 Clutch disc wrench

Removing shaft nut and clutch disc

NT351

KV99106800 Pulley installer

Installing pulley

NT352

CSV613 compressor Tool number Tool name

Description

KV99106100 Clutch disc wrench

Removing center bolt

When replacing the magnet clutch in the above compressor, use a clutch disc wrench with the pin side on the clutch disc to remove it.

NT232

Pin

Clutch disc wrench NT378

HA-7

PRECAUTIONS AND PREPARATION Special Service Tools (Cont’d) Tool number Tool name

Description

KV99232340 or KV99107400 Clutch disc puller

Removing clutch disc

NT376

KV99106200 Pulley installer

Installing pulley

NT235

HFC-134a (R-134a) Service Tools and Equipment Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubrication oil. Separate and non-interchangeable service equipment must be used for each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor failure will result. Tool name

Description

Note Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size ● large container 1/2”-16 ACME

HFC-134a (R-134a) refrigerant

NT196

Nissan A/C System Oil Type R (Part No.: KLH00-PAGR0) Type S (Part No: KLH00-PAGS0)

Type: Poly alkyline glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Capacity: 40m (1.4 Imp fl oz)

NT197

Recovery/Recycling/ Recharging equipment

Function: Refrigerant Recovery and Recycling and Recharging

NT195

HA-8

PRECAUTIONS AND PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool name

Description

Note Power supply: ● DC 12 V (Cigarette lighter)

Electrical leak detector

NT198

Manifold gauge set (with hoses and couplers)

Identification: ● The gauge face indicates R-134a. Fitting size: Thread size ● 1/2”-16 ACME

NT199

Service hoses High side hose ● Low side hose ● Utility hose

Hose color: ● Low hose: Blue with black stripe ● High hose: Red with black stripe ● Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: ● 1/2”-16 ACME

●

NT201

Hose fitting to service hose: ● M14 x 1,5 fitting is optional or permanently attached.

Service couplers High side coupler ● Low side coupler ●

NT202

Refrigerant weight scale

For measuring of refrigerant Fitting size: Thread size ● 1/2”-16 ACME

NT200

Vacuum pump (Including the isolator valve)

Capacity: ● Air displacement: 4 CFM ● Micron rating: 20 microns ● Oil capacity: 482 g (17 oz) Fitting size: Thread size ● 1/2”-16 ACME NT203

HA-9

PRECAUTIONS AND PREPARATION Precautions for Service Equipment RECOVERY/RECYCLING/RECHARGING EQUIPMENT Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance. With isolator valve

Hose fittings: 1/2”-16ACME

Isolator valve Open

Close Without isolator valve Shut off valve

VACUUM PUMP The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure, so the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hose-to-pump connection, as follows: ● Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. ● For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. ● If the hose has an automatic shut off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended.

RHA270D

MANIFOLD GAUGE SET Be certain that the gauge face indicates R-134a or 134a. Be sure the gauge set has 1/2”-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.

1/2′′-16ACME

SHA533D

Hose fittings to manifold gauge orrecovery/recycling equipment; 1/2”-16ACME

Black stripe M14 × 1.5 fitting optional (Hose may be permanentlyattached to coupler)

SERVICE HOSES Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

RHA272D

HA-10

PRECAUTIONS AND PREPARATION Precautions for Service Equipment (Cont’d) SERVICE COUPLERS

Shut-off valve

A/C service valve

M14 × 1.5 fitting optional (Hose may be permanentlyattached to coupler)

Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

Close

RHA273D

REFRIGERANT WEIGHT SCALE Refrigerant container (HFC-134a)

Hose fittings: 1/2′′-16ACME

Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME.

To manifold gauge

Weight scale

RHA274D

CHARGING CYLINDER Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/ recharge equipment.

HA-11

DESCRIPTION Refrigeration Cycle REFRIGERANT FLOW The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank, evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.

FREEZE PROTECTION Variable displacement (CSV613) Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, therefore temperature, is controlled by the CSV613 variable displacement compressor to prevent freeze up.

Vane rotary (CR-14) The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the thermo control amplifier allows compressor operation.

REFRIGERANT SYSTEM PROTECTION Dual-pressure switch (System with CR-14 compressor) The refrigerant system is protected against excessively high or low pressure by the dual-pressure switch, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the dualpressure switch opens to interrupt the compressor operation.

Pressure sensor (System with CSV613 compressor) The pressure sensor is located on the liquid tank. It converts the system pressure into a voltage value witch is then input into ECM. If the system pressure rises above, or falls below the specifications, ECM interrupt the compressor operation.

Fusible plug Open at temperatures above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug is melted and opened, check the refrigerant line and replace liquid tank.

Pressure relief valve (CSV613 compressor) The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

HA-12

DESCRIPTION Refrigeration Cycle (Cont’d) Pressure relief valve (CSV613 only)

Compressor

High-pressure gas

Low-pressure liquid

High-pressure liquid

Low-pressure gas

Outside air

Condenser

Evaporator Blower motor Liquid tank

Expansion valve Dual-pressure switch/ pressure sensor

HA-13

RHA896FA

DESCRIPTION CSV613 Variable Displacement Compressor GENERAL INFORMATION 1. The CSV613 compressor differs from previous units. The vent temperatures of the CSV613 compress or do not drop too far below 5°C (41°F) when: ● evaporator intake air temperature is less than 20°C (68°F) ● engine is running at speeds less than 1,500 rpm. This is because the CSV613 compressor provides a means of “capacity” control. 2. The CSV613 compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. 3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem. 4. For air conditioning systems with the CSV613 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. 5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm2, 21 to 26 psi) under varying conditions. In previous compressors, however, suction pressure was reduced with increases in engine speed.

HA-14

DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) DESCRIPTION General The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 6 to 125 cm3 (0.366 to 7.63 cu in). Journal pin

Swash plate Rear Head

Seal

Discharge valve plate

Shaft

Control valve Oil drain bolt

Cylinder Piston

Long stroke (Large amount of refrigerant discharge) Swash plate tilting angle changes

Short stroke (Small amount of refrigerant discharge)

Discharge capacity cm3 (cu in)/rev.

Pistonstroke length mm (in)

Minimum

6 (0.366)

1.2(0.039)

Maximum

125 (7.63)

25.9 (1.02)

Discharge control

Journal pin

Drive lug

KHA103

HA-15

DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) Operation 1. Operation control valve Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure. 2. Maximum cooling Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes: ● the crankcase’s internal pressure to equal the pressure on the low-pressure side; ● the cylinder’s internal pressure to be greater than the crankcase’s internal pressure. Under this condition, the swash plate is set to the maximum stroke position.

Discharge port

Cylinder pressure

Crankcase

Suction port

Crankcase pressure

Low-pressure valve: Open Spring pressure Bellows

Forces needed to increase stroke Valve position for lowering crankcase pressure RHA473C

HA-16

DESCRIPTION CSV613 Variable Displacement Compressor (Cont’d) 3. Capacity control ● Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low. ● The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.77 bar, 1.8 kg/cm2, 26 psi). Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase. ● The force acts around the journal pin near the swash plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate.

Discharge port

Low-pressure valve: Open

Crankcase

Cylinder pressure

Crankcase pressure Suction port

Spring pressure

Forces needed to increase stroke Valve position for lowering crankcase pressure RHA474C

HA-17

DESCRIPTION Component Layout SEC. 270⋅271⋅272⋅273

Side defroster nozzle

Defroster nozzle

Side defroster nozzle

Side ventilator duct Center ventilator duct

Side ventilator duct

Heater unit

Fresh vent control lever

Cooler unit Intake unit For Scandinavian models only: Rear heater duct (Whenremoving rear heater duct, it is necessary to remove frontseats.) Control assembly (Heater)

Control assembly (Air conditioner)

KHA104

HA-18

HEATER

DESCRIPTION Control Operation LHD models

Temperature control knob

Fan control knob

Mode control knob

.

Recirculation switch

Rear defroster switch

RHD models

Mode control knob

Temperature control knob

Fan control knob

Recirculation switch Rear defroster switch

KHA105

FAN CONTROL KNOB This knob turns the fan ON and OFF, and controls fan speed.

MODE CONTROL KNOB This knob controls the outlet air flow.

TEMPERATURE CONTROL KNOB This knob allows adjustment of the temperature of the outlet air.

RECIRCULATION (REC) SWITCH OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.

Air Flow FRESH VENT SYSTEM This system is controlled by means of the fresh air vent lever which is mechanically linked to the fresh vent door by the control cable. Fresh vent air always comes from the center vent in any mode when the fresh air vent lever is set at the blue dot position. Fresh air vent control lever

Set at blue dot position

To defroster Heater core Evaporator Outside air

To floor Fresh air vent control cable

To floor

KHA064

HA-19

DESCRIPTION

AUTO

Introduction The automatic temperature control (ATC) system provides automatic regulation of the discharged air temperature and the discharged air volume (Blower speed). The air outlet door, intake door and compressor magnet clutch are controlled by the manual operation of each switch.

Features Air mix door control (Automatic temperature control) The air mix door is automatically controlled so that in-vehicle temperature will reach, and be maintained at the operator selected “set temperature”. For a given set temperature, the air mix door position will depend on: Ambient temperature, in-vehicle temperature, amount of sunload, set temperature and A/C switch signals. Fan speed control When the fan control switch is in the Auto position, the blower speed is automatically controlled, depending on: Ambient temperature, in-vehicle temperature, amount of sunload, set temperature, and A/C switch signals. It is also controlled by the manual operation of the fan control switch. Starting fan speed control When engine coolant temperature is low, the air outlet door position is detected by the A/C control panel and if this is set in B/L, FOOT or FOOT/DEF blower speed is controlled to prevent a large amount of cold air from being discharged into the floor area. Outlet door control This can be selected by operation of the mode control knob. Intake door control This can be selected by changing the REC switch position. Compressor magnet clutch control System with CR-14 compressor When the A/C switch is ON, the thermistor detects evaporator temperature. The thermo control amplifier controls clutch ON/OFF operation depending on the evaporator temperature. System with CSV613 compressor Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore temperature, is controlled by the CSV613 variable displacement compressor to prevent freeze up.

HA-20

AUTO

DESCRIPTION Control Operation

The control system consist of a) input sensors and switches, b) the automatic amplifier (microcomputer), and c) outputs. The relationship of these components is shown in the diagram below: Control unit

● Set temperature Control (Potentio temperature control)

Ambient sensor

In-vehicle sensor

Sunload sensor

Air mix door motor

Automatic amplifier (Micro- computer)

Air mix door

PBR (Potentio Balance Resistor)built-into air mix door motor

Thermal transmitter Blower motor

Fan

KHA111

Auto air conditioner Air conditioner switch

Mode control knob

Auto switch

Fan control

Temperature control switch (PTC)

Rear window defogger switch

Recirculation switch

KHA112

HA-21

DESCRIPTION Control Operation (Cont’d)

AUTO

FAN CONTROL SWITCH Manual control of the blower speed. Four speeds are available for manual control (as shown on the display screen): low I, medium low II, medium high III, high IIII

MODE CONTROL KNOB This knob controls outlet air flow. ) mode, the intake door is set to “FRESH”, and the A/C on. In “DEF” (

AUTO SWITCH The air mix door, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.

TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) Increases or decreases the set temperature.

RECIRCULATION (REC) SWITCH OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. RECIRC is canceled when DEF mode is selected.

AIR CONDITIONING SWITCH The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The display screen indicates “A/C”. A/C switch will turn on when DEF mode is selected. The air conditioner cooling function operates only when the engine is running.

HA-22

AUTO

DESCRIPTION Discharge Air Flow p1 p2

: Ventilation

p3

: Foot

★ : Air flow in REC position

: Defroster

p3

p3

Foot

p3

p3

To defroster

p3 Outside air

p2

p2

To floor

p2

To floor

Foot and defroster Vent

p3 p1

To ventilator

To defroster

Defroster door Fresh vent door Heater core Intake air ★ Outside air

p2

To floor

Floor door

p2

Air mix door Ventilator door

To floor

Intake door Defroster

Bi-level

p1

p3

To defroster

To ventilator Outside air

Outside air

p2

To floor

p2

Air passed through heater core

To floor

Mixed air (

+

)

Air not passed through heater core

This illustration is for LHD models. The layout for RHD models issymmetrically opposite.

KHA113

HA-23

TROUBLE DIAGNOSES

HEATER

Operational Check The purpose of the operational check is to confirm that the system operates as it should. The systems which are checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase.

CONDITIONS: Engine running at normal operating temperature.

PROCEDURE: 1. Check blower 1) Turn fan control knob to 1-speed. Blower should operate on 1-speed. 2) Then turn fan control knob to 2-speed. 3) Continue checking blower speed until all four speeds are checked. 4) Leave blower on 4-speed. KHA106

2. Check discharge air 1) Turn mode control knob.

KHA107

2) Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” in “DESCRIPTION” (HA-23).

Discharge airflow

Switch mode/ indicator

Airoutlet/distribution Face

Foot

Defroster

100%

—

—

60%

40%

—

15%*

65%

20%

15%*

55%

30%

15%*

—

85%

* Face air from SIDE VENT only KHA032

HA-24

TROUBLE DIAGNOSES Operational Check (Cont’d)

HEATER

3. Check recirculation 1) Press recirculation switch. Recirculation indicator should light. 2) Listen for intake door position change (you should hear blower sound change slightly).

KHA108

4. Check temperature decrease 1) Turn temperature control knob to full cold. 2) Check for cold air at discharge air outlets.

KHA109

5. Check temperature increase 1) Turn temperature control knob to full hot. 2) Check for hot air at discharge air outlets.

KHA110

HA-25

AUTO

TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick and Accurate Repair WORK FLOW F

CHECK IN

Reference item

H

LISTEN TO CUSTOMER COMPLAINT AND CONFIRM BY PERFORMING OPERATIONAL CHECK.

F

Operational check (Refer to HA-24.) Symptom Chart (Refer to HA-28.)

H

INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELATED TO EACH SYMPTOM.

F

Symptom Chart (Refer to HA-28.)

H E

ELIMINATE GOOD SYSTEM(S)/PART(S).

F

Preliminary Check (Refer to HA-30.)

F

Main Power Supply and Ground Circuit Check (Refer to HA-51.)

H

CHECK MAIN POWER SUPPLY AND GROUND CIRCUITS. H ●

●

Diagnostic Procedure(s) (Refer to HA-32.) Circuit Diagram (Refer to HA-41.)

E

ELIMINATE GOOD PART(S)/HARNESS(ES)/ CONNECTOR(S) ELECTRICALLY.

F

Malfunctioning part(s)

Malfunctioning harness(es)/ connector(s)

H

INSPECT EACH COMPONENT. H

H

REPAIR.

NG

Harness layout (Refer to “HARNESS LAYOUT” in EL section for details.

REPAIR/REPLACE.

H

H

FINAL CHECK OK H

CHECK OUT

HA-26

F

Electrical Components Inspection (Refer to HA-78.)

TROUBLE DIAGNOSES

NOTE

HA-27

AUTO

AUTO

TROUBLE DIAGNOSES Symptom Chart

HA-51 Auto amp.

HA-51

q

q

q

q

Blower motor does not rotate at all. (Fan switch [AUTO] [1] [2] [3] [4])

q

q

Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3 or 4-speed.)

q

q

q

Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in Hi or MH.)

q

q

q

Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LO.)

q

q

q

SYMPTOM A/C does not blow cold air.

q

q

q

15A Fuses

A/C control panel

HA-77 Diagnostic Procedure 14

7.5A Fuse

HA-76

HA-69 Diagnostic Procedure 9

Diagnostic Procedure 13

HA-68 Diagnostic Procedure 7

HA-75

HA-66 Diagnostic Procedure 6

Diagnostic Procedure 12

HA-65 Diagnostic Procedure 5

HA-74

HA-61 Diagnostic Procedure 4

Diagnostic Procedure 11

HA-57 Diagnostic Procedure 3

HA-70

HA-56 Diagnostic Procedure 2

Diagnostic Procedure 10

HA-52

HA-32 Preliminary check 3

Diagnostic Procedure 1

HA-31

HA-51

Main Power Supply and Ground Circuit Check

Diagnostic Procedure

Preliminary check 2

Preliminary check 1

REFERENCE PAGE

HA-30

PROCEDURE

HA-51

Preliminary Check

DIAGNOSTIC TABLE

Starting fan speed control does not operate.

q

q

There is too much difference between setting temp. on P.T.C. and in-vehicle temp.

q

q

Air mix door motor does not operate normally.

q

q

Intake door does not change in VENT, B/L FOOT DEF or FOOT mode.

q

Magnetic clutch does not engage when A/C switch and fan switch are ON.

q

Ambient sensor circuit is open or shorted.

q

q

In-vehicle sensor circuit is open or shorted.

q

q

Sunload sensor circuit is open or shorted.

q

q

Thermal transmitter circuit is open or shorted.

q

q

Illumination or indicators of control unit do not come on.

q

Noise

, : The number means checking order. q: As for the order of inspection, refer to each flow chart. (It depends on malfunctioning portion.)

HA-28

q

—

REC switch

q q

q q q

q q q q

q q q q

q q q q

q q q

q

q q HA-86 Refer to EL section.

Air mix door PBR Intake door motor Auto amp. Ambient sensor In-vehicle sensor Sunload sensor Thermal transmitter

q q q q q q q q q

q q q

q q q q

q

q

HA-29 q

q

q q

q q q

q

q

q q q q q

q q q q q

Harness

Refer to EL section.

q

—

HA-113

HA-70

q

Compressor

Illumination system

HA-80

Thermo control amp.

Refer to EC section.

HA-98

HI relay

ECM

HA-98

MH relay

Thermal protector

HA-98

ML relay

HA-79

HA-98

LO relay

Magnetic clutch

q

Pressure switch/sensor

HA-87

A/C relay

HA-85

HA-86

HA-51

HA-81

HA-94

HA-93

HA-84

PTC

—

Fan switch

Control unit

—

A/C switch

q —

—

Fan resistor

Blower motor

TROUBLE DIAGNOSES Symptom Chart (Cont’d) AUTO

Electrical Components Inspection

q q

q q q

q q q

q

q q q q q

q

q q q q q

q

q q

q

q

q

q

AUTO

TROUBLE DIAGNOSES Checking Resistor

Checking resistors are used for trouble diagnoses of blower motor operation and air mix door motor operation. Use checking resistor when inspecting portions with C/R *1, C/R *2 in flow chart. CAUTION: Select checking resistors which have resistance values corresponding with those indicated in table below, and connect to respective sensors. Checking resistor Blower motor operation check Air mix door motor operation check

Ambient sensor

In-vehicle sensor

Wattage

1,500Ω

C/R *1 1,000Ω

1/4W 2,490Ω

C/R *2

1. Disconnect ambient sensor and in-vehicle sensor harness connectors. 2. Connect checking resistors to ambient sensor harness connector and in-vehicle sensor harness connector when inspecting portions with C/R *1, C/R *2 in flow chart in trouble diagnoses. 3. Turn ignition switch ON. 4. Turn A/C switch ON. 5. Turn VENT mode. 6. Keep sunload sensor away from sunlight by covering it.

Preliminary Check PRELIMINARY CHECK 1 Intake door is not set at “FRESH”. Is intake door in “Fresh” position when REC switch is turned from ON to OFF with ignition switch at ON? (Can you hear air moving from the intake unit?)

No

E

Go to Diagnostic Procedure 9 (HA-69).

E

Go to Diagnostic Procedure 9 (HA-69).

Yes H

Is intake door in “REC” position when REC switch is turned from OFF to ON with ignition switch at ON? (Can you hear air moving from the intake unit?) Yes H

INSPECTION END

HA-30

No

AUTO

TROUBLE DIAGNOSES Preliminary Check (Cont’d) PRELIMINARY CHECK 2 A/C does not blow cold air. DOES AIR FLOW FROM VENTS? Condition ● Engine running at operating temperature. ● Ignition switch, A/C switch, and fan switch are ON. ● Mode control knob is in VENT mode and temperature control knob is in full cold position.

No

E

IS BLOWER MOTOR OPERATING NORMALLY? Yes

CHECK BLOWER MOTOR OPERATION. Go to Diagnostic Procedure 1 (HA-52).

Yes

CHECK COMPRESSOR BELT TENSION. Refer to “Checking Drive Belts” in MA section. NG

NG F

H

H

CHECK COMPRESSOR OPERATION.

CHECK FOR EVAPORATOR COIL FREEZE UP. Remove intake unit. Check if evaporator freezes.

OK

OK

NG (Freezes up.) H

H

NG

OK

Go to Diagnostic Procedure 10 (HA-70).

H

CHECK VENTILATOR DUCT FOR AIR LEAKS.

OK

H

H

H

CHECK THERMO CONTROL AMP. AND A/C RELAY OPERATION.

Go to Performance Test Diagnoses.

CHECK AMOUNT OF REFRIGERANT. Check amount of refrigerant using refrigerant recovery & recharging equipment. NG

H

CHECK WATER COCK OPERA- NG TION. Warm up engine before checking.

CHECK FOR REFRIGERANT LEAKS.

CHECK VENTILATOR DUCT FOR AIR LEAKS.

OK (Does not freeze up.) H

CHECK REFRIGERATION CYCLE PRESSURE WITH RECOVERY/RECYCLING EQUIPMENT CONNECTED. Refer to Performance Chart.

Adjust or replace compressor belt. Refer to MA section (“ENGINE MAINTENANCE”).

H

No H

OK F

H

OK

CHECK EVAPORATOR OUTLET AIR TEMPERATURE. Refer to Performance Chart. H

NG

CHECK AIR MIX DOOR OPERATION. (Refer to HA-90.)

HA-31

E

Adjust or replace water cock.

AUTO

TROUBLE DIAGNOSES Preliminary Check (Cont’d) PRELIMINARY CHECK 3 Noise Check where noise comes from.

H

Blower motor

H

H

Check for noise in all modes and temperature settings.

H

Compressor H

OK

Replace expansion valve.

H

H

Check blower motor and fan for wear.

H

The line is fixed directly to the body.

NG

H

Check blower motor for foreign particles.

H

Refrigerant line

Belt

H

Inspect the compressor clutch and pulley and idler pulley.

Noise is constant.

H

Expansion valve

H

Replace compressor clutch and pulley. Refer to HA-111, 114.

Fix the line with rubber or some vibration absorbing material.

H

The line is not fixed.

H

Fix the line tightly.

H

Check disc-to-pulley clearance. Refer to HA-113, 116. OK H

Noise is intermittent. H Check air discharge ducts for obstructions, foreign materials or air leakage.

H

The belt vibration is intense.

Check and adjust lubricant.

H

Side of belt is worn out.

OK H

H

Replace compressor and liquid tank.

Readjust belt tension. Refer to MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”).

HA-32

H

The pulley center does not match. Readjust the pulley center.

AUTO

TROUBLE DIAGNOSES Performance Test Diagnoses INSUFFICIENT COOLING INSUFFICIENT COOLING H

NG

CHECK AIR FLOW. OK H

E

CHECK BLOWER MOTOR OPERATION. H

CHECK COMPRESSOR OPERATION. OK

OK

H

Clogged blower inlet/ Clogged duct/Loose duct connection/Air leakage, etc.

NG H

NG

A p

(Go to next page.)

B p

(Go to next page.) OK

H

CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA-35.)

RECOVER REFRIGERANT USING RECOVERY RECYCLING EQUIPMENT AND CHARGE SPECIFIED AMOUNT OF REFRIGERANT.

NG

F

H

H

CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA-35.)

BOTH HIGH AND LOW PRESSURE SIDES ARE TOO HIGH.

Note E

H E

CHECK DISCHARGE AIR TEMPERATURE. USE PERFORMANCE CHART. (Refer to HA-35.) NG

OK

HIGH PRESSURE SIDE IS TOO HIGH AND LOW PRESSURE SIDE IS TOO LOW.

E

HIGH PRESSURE SIDE IS TOO LOW AND LOW PRESSURE SIDE IS TOO HIGH.

E

BOTH HIGH AND LOW PRESSURE SIDES ARE TOO LOW.

E

LOW PRESSURE SIDE SOMETIMES BECOMES NEGATIVE.

E

LOW PRESSURE SIDE BECOMES NEGATIVE.

E

H

END

H

Malfunctioning temperature control operation (air mix door position improperly adjusted)/ Malfunctioning water cock operation (incorrect valve closure)

Note:

− correspond to those in TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE. (Refer to HA-36.)

HA-33

TROUBLE DIAGNOSES Performance Test Diagnoses (Cont’d)

AUTO

A p

H

Malfunctioning blower motor fan

H

Loose fan/Improper contact of fan and case/Deformed fan

H

H

Malfunctioning electrical circuit

Malfunctioning blower motor internal circuit

H

Discontinued wiring or component circuits or poor connection/ Malfunctioning resistor, amplifier, etc./ Burned out fuse or low battery voltage.

B p

H

Magnet clutch does not engage.

H

H

Magnet clutch slipping

Belt slipping

H

H

CHECK MAGNET CLUTCH (coil circuit, disc-to-pulley clearance).

CHECK COMPRESSOR BELT AND BELT TENSION.

H

CHECK ELECTRICAL CIRCUIT (wiring, components circuit).

E

Malfunctioning internal parts of clutch, compressor

H

CHECK ACTIVATION OF SAFETY/PROTECTION DEVICES (such as pressure switch, etc.).

E

E

HA-34

Foreign particles on clutch frictional surface or excessive disc clearance

Malfunctioning electrical circuit (poor connection, low battery voltage, etc.)

AUTO

TROUBLE DIAGNOSES A/C Performance Chart TEST CONDITION

Testing must be performed as follows: Vehicle location: Indoors or in shade (in a well ventilated place) Doors: Closed Door window: Open Temp lever position: Max COLD Mode switch position: Ventilation Intake switch position: Recirculation Fan switch position: Max Engine speed: Idling 825-850 rpm

TEST READING (RHD & LHD MODELS) Recirculating-to-discharge air temperature table Inside air (Recirculating air) at blower assembly inlet Relative humidity %

Discharge air temperature at center ventilator °C (°F)

Air temperature °C (°F)

50 - 60

60 - 70

20 (68)

6.4 - 8.0 (44 - 46)

25 (77)

10.6 - 12.4 (51 - 54)

30 (86)

14.6 - 17.0 (58 - 63)

35 (95)

19.0 - 22.0 (66 - 72)

40 (104)

23.3 - 27.2 (74 - 81)

20 (68)

8.0 - 9.6 (46 - 49)

25 (77)

12.4 - 14.6 (54 - 58)

30 (86)

17.0 - 19.7 (63 - 67)

35 (95)

22.0 - 24.9 (72 - 77)

40 (104)

27.2 - 30.2 (81 - 86)

Ambient air temperature-to-operating pressure table Ambient air Relative humidity %

50 - 70

High-pressure (Discharge side) kPa (bar, kg/cm2, psi)

Low-pressure (Suction side) kPa (bar, kg/cm2, psi)

20 (68)

736 - 902 (7.36 - 9.02, 7.5 - 9.2, 107 - 131)

118 - 186 (1.18 - 1.86, 1.2 - 1.9, 17 - 27)

25 (77)

873 - 1098 (8.73 - 10.98, 8.9 - 11.2, 127 - 159)

137 - 216 (1.37 - 2.16, 1.4 - 2.2, 20 - 31)

30 (86)

1,079 - 1,275 (10.79 - 12.75, 11.0 - 13.0, 156 - 185)

157 - 245 (1.57 - 2.45, 1.6 - 2.5, 23 - 36)

35 (95)

1,304 - 1,608 (13.04 - 16.08, 13.3 - 16.4, 189 - 233)

206 - 304 (2.06 - 3.04, 2.1 - 3.1, 30 - 44)

40 (104)

1,550 - 1,912 (15.50 - 19.13, 15.8 - 19.5, 225 - 277)

255 - 363 (2.55 - 3.63, 2.6 - 3.7, 37 - 53)

Air temperature °C (°F)

HA-35

TROUBLE DIAGNOSES

AUTO

Trouble Diagnoses for Abnormal Pressure Whenever the system’s high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the standard (normal) pressure, differs from vehicle to vehicle, refer to HA-35 (“Ambient air temperature-tooperating pressure table”). Gauge indication

Refrigerant cycle

Probable cause

Reduce refrigerant until specified pressure is obtained. Insufficient condenser cooling ● Clean condenser. performance ● Check and repair cooling " fan as necessary. 1 Condenser fins are p clogged. 2 Improper cooling fan p rotation. Evacuate repeatedly and ● Low-pressure pipe is not Poor heat exchange in conrecharge system. cold. denser (After compressor operation ● When compressor is stops, high pressure stopped high-pressure decreases too slowly.) value quickly drops by AC359A " approximately 196 kPa (2.0 Air in refrigeration cycle. bar, 2 kg/cm2, 28 psi). It then decreases gradually thereafter. Engine tends to overheat. Engine cooling systems mal- Check and repair each function. engine cooling system. ● An area of the low-pres● Excessive liquid refrigerant Replace expansion valve. sure pipe is colder than on low-pressure side areas near the evaporator ● Excessive refrigerant disoutlet. charge flow ● Plates are sometimes cov● Expansion valve is open a ered with frost. little compared with the specification. " 1 Improper thermal valve p installation. 2 Improper expansion p valve adjustment. High-pressure side is too high Upper side of condenser and High-pressure tube or parts ● Check and repair or and low-pressure side is too high-pressure side are hot, located between compressor replace malfunctioning low. however, liquid tank is not so and condenser are clogged parts. or crushed. hot. ● Check lubricant for contamination.

Both high and low-pressure sides are too high.

Pressure is reduced soon after water is splashed on condenser. Air suction by cooling fan is insufficient.

●

Excessive refrigerant charge in refrigeration cycle.

Corrective action

AC360A

HA-36

AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Cont’d) Gauge indication

Refrigerant cycle

High-pressure side is too low and low-pressure side is too high.

Probable cause

Corrective action

High and low-pressure sides become equal soon after compressor operation stops.

Compressor pressure operation is incorrect. " Damage inside compressor packings.

Replace compressor.

No temperature difference between high and low-pressure sides.

Compressor operation is incorrect. " Damage inside compressor packings.

Replace compressor.

There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. ● Liquid tank inlet and expansion valve are frosted. ● Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. ● Expansion valve inlet may be frosted. ● Temperature difference occurs somewhere in highpressure side. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.

Liquid tank inside is clogged a little.

●

High-pressure pipe located between liquid tank and expansion valve is clogged.

●

AC356A

Both high- and low-pressure sides are too low.

AC353A

Both high- and low-pressure sides are too low.

AC353A

●

Expansion valve closes a little compared with the specification. " 1 Improper expansion p valve adjustment. 2 Malfunctioning thermal p valve. 3 Outlet and inlet may be p clogged. Low-pressure pipe is clogged An area of the low-pressure pipe is colder than areas near or crushed. the evaporator outlet. Air flow volume is not enough Compressor operation is or is too low. incorrect. " Damaged inside compressor packings.

HA-37

●

●

●

●

Replace liquid tank. Check lubricant for contamination.

Check and repair malfunctioning parts. Check lubricant for contamination.

Remove foreign particles by using compressed air. Check lubricant for contamination.

Check and repair malfunctioning parts. ● Check lubricant for contamination. Replace compressor. ●

AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Cont’d) Gauge indication

Refrigerant cycle

Low-pressure side sometimes becomes negative.

●

●

Probable cause

Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted.

Corrective action Drain water from refrigerant or replace refrigerant. Replace liquid tank.

Refrigerant does not discharge cyclically. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant.

●

High-pressure side is closed and refrigerant does not flow. " Expansion valve or liquid tank is frosted.

Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles. ● If water is the cause, initial cooling is okay, then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. ● If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). ● If either of the above methods cannot correct the problem, replace expansion valve. ● Replace liquid tank. ● Check lubricant for contamination.

●

AC354A

Low-pressure side becomes negative.

Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed.

AC362A

HA-38

AUTO

TROUBLE DIAGNOSES Component Location

A/C control panel

In-vehicle sensor

A/C relay

Sunload sensor Intake door motor

Blower motor fan resistor .

Blower fan motor relay

.

Ambient sensor

Air mix door motor

Auto amp. HI.ML.LH.LO relay

Triple-pressure switch (With dieselengine) Dual-pressure switch (With GA engine) Pressure sensor (SRand QG engine)

Compressor

.

. .

Compressor

.

Triple-pressure switch

Dual-pressure switch/sensor

Ambient sensor .

A/C relay

LO relay .

.

Auto amp.

Fuse block (J/B)

.

. .

Blower fan motor relay ● Behind fuse block (J/B)

.

ML relay

HI relay

MH relay

.

Blower motor

Fan resistor

Air mix door motor

Intake door motor .

.

Sunload sensor

.

In-vehicle sensor

A/C control panel NHA290

HA-39

AUTO

TROUBLE DIAGNOSES Wiring Diagram — HEATER — IGNITION SWITCH ON

IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

BLOWER MOTOR

Refer to EL-POWER.

INTAKE DOOR MOTOR FRE REC

FAN RESISTOR

RECIRCULATION SWITCH REC

FRE

REC

FRE

FAN SWITCH OFF

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YHA336

HA-40

AIR MIX DOOR MOTOR

FAN RESISTOR

BLOWER MOTOR

HA-41 INVEHICLE SENSOR

A/C AUTO AMP

A/C LOW RELAY

A/C ML RELAY

A/C MH RELAY

A/C HIGH RELAY

FUSE

IGNITION SWITCH ON

INTAKE DOOR MOTOR

AMBIENT SENSOR

SUN LOAD SENSOR

To illumination system

THERMAL TRANSMITTER

A/C CONTROL PANEL

COMBINATION METER (WATER TEMPERATURE GAUGE)

REFRIGENT PRESSURE SENSOR

THERMO CONTROL AMPLIFIER

FUSE

AIR CONDITIONER RELAY

IGNITION SWITCH ON or START

COMPRESSOR

THERMAL PROTECTOR

COOLING FAN MOTOR-1

COOLING FAN RELAY-1

IACV-FIDC SOLENOID VALVE

COOLING FAN MOTOR-2

DUALPRESSURE SWITCH

TRIPLEPRESSURE SWITCH

COOLING FAN MOTOR-2

COOLING FAN RELAY-1

COOLING FAN RELAY-3

FUSIBLE LINK

: With GA engine or diesel engine

: With SR engine or QG engine

: With GA engine

: With diesel engine

: With gasoline engine

COOLING FAN RELAY-2

COOLING FAN MOTOR-1

FUSIBLE LINK

BATTERY

TROUBLE DIAGNOSES AUTO

Circuit Diagram — Air Conditioner

YHA337

AUTO

TROUBLE DIAGNOSES Wiring Diagram — A/C — IGNITION SWITCH ON or START Refer to EL-POWER FUSE BLOCK (J/B)

To EL-ILL

SIDE LIGHT

SIDE LIGHT

A/C CONTROL PANEL

To HA-A/C-03

A/C AUTO AMP

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YHA338

HA-42

AUTO

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

HA-A/C-02 IGNITION SWITCH ON

15A 7

15A 10

FUSE BLOCK (J/B)

Refer to EL-POWER

M1

6B L/Y

L/Y 1

M

BLOWER MOTOR

M30

2 L/B

L/B

11

L/B

L/B

B

Next page

L/B 5 FAN RESISTOR

M29 6

7

8

L/R

L/Y

L/W

M84

M112

L/W

14

L/W

L/W

C

L/Y

13

L/Y

L/Y

D

L/R

12

L/R

L/R

E

Next page

REFER TO THE FOLLOWING

M1 6 8 5 7 M29 BR

1 2

M30 W

FUSE BLOCK - Junction Box (J/B)

16 14 13 12 11 15 M84 W

YHA229

HA-43

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

AUTO

YHA376

HA-44

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

AUTO

YHA377

HA-45

AUTO

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) IGNITION SWITCH ON Refer to EL-POWER. FUSE BLOCK (J/B)

To HA-A/C-07

Next page

INTAKE DOOR MOTOR

THERMISTOR

THERMO CONTROL AMPLIFER To HA-A/C-07

To HA-A/C-09 Next page

To HA-A/C-07

Next page

A/C CONTROL PANEL

AIR MIX DOOR MOTOR

: With diesel engine : With GA engine A/C AUTO AMP.

:With GA engine or diesel engine : With SR engine or QG engine

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YHA341

HA-46

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

AUTO

WITH SR ENGINE or QG ENGINE

Preceding page

FUSE BLOCK (J/B)

AIR CONDITIONER RELAY

REFRIGERANT PRESSURE SENSOR

COMPRESSOR

CVT models ECM

MT models

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) ELECTRICAL UNITS

YHA342

HA-47

AUTO

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) WITH GA ENGINE or DIESEL ENGINE

To HA-A/C-05

LOW

HIGH

DUAL-PRESSURE SWITCH

AIR CONDITIONER RELAY

NORMAL

To HA-A/C-09

: With GA engine : With diesel engine

Lotemp

ECM

Hitemp

THERMAL PROTECTOR

IACV-FICD SOLENOID VALVE

COMPRESSOR

REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YHA343

HA-48

AUTO

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d) WITH GASOLINE ENGINE IGNITION SWITCH ON or START

HA-A/C-08

BATTERY

Refer to EL-POWER.

10A 11

M1 SQ

5H

BR

BR

BR

, E127

G

GA

17C

12

40A f

FUSE BLOCK (J/B)

M70 E125 GA SQ BR

G

2

3

1

5

LG/R

G/B

COOLING FAN RELAY-1

E45

G/B LG/R

*

GA

: With GA engine

SQ

: With SR engine or QG engine

*

1

*2

1

LG/R

SQ

: E42

GA

: E65

SQ

:

GA

: F70

F4

G/B 1

1

M

COOLING FAN MOTOR-1

M

E19 2

2

B

B

COOLING FAN MOTOR-2

E28 :

SQ

E94 :

GA

SQ : 7 GA : 4 LG/R

SQ : 13

2 RFRL

*

GA : 9

ECM F101

B

B

E11

E37

REFER TO THE FOLLOWING

M1

3 1 2

1

E19 , E28 , E94 B GY B

1 2 3 4 5 6 7 8 9 10

F4 GY

2 5

1

2 3 4 5 6 7 8 9

E45 B

1 2 3 4 5 6 7 E125 8 9 10 11 12 13 14 15 16 BR

FUSE BLOCK - Junction Box (J/B)

E127 FUSE BLOCK - Junction Box (J/B) F101 ELECTRICAL UNITS

F70 GY

YHA235

HA-49

TROUBLE DIAGNOSES Wiring Diagram — A/C — (Cont’d)

AUTO

WITH DIESEL ENGINE IGNITION SWITCH ON or START

BATTERY

Refer to EL-POWER

FUSE BLOCK (J/B)

COOLING FAN MOTOR-1

COOLING FAN RELAY-3

COOLING FAN RELAY-1

COOLING FAN RELAY-2

To HA-A/C-07

NORMAL

HIGH HIGH

LOW

COOLING FAN MOTOR-2

TRIPLEPRESSURE SWITCH

LOW

ECM To HA-A/C-05

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) ELECTRICAL UNITS

YHA344

HA-50

AUTO

TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR AUTO A/C SYSTEM Check power supply circuit for auto air conditioning system. Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.

A/C CONTROL PANEL Check power supply circuit for A/C control panel unit with ignition switch ON. 1. Disconnect A/C control panel harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. p 1 and body ground.

A/C control panel connector

Voltmeter terminal

! YHA237

@

1 p

Body ground

Voltage Approx. 12V

Check body ground circuit for A/C control panel with ignition switch OFF. 1. Disconnect A/C control panel harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. p 2 , p 8 , p 14 , p 20 and body ground.

A/C control panel connector

Ohmmeter terminal

!

@

2 p 8 p 14 p 20 p

A/C control panel connector

Body ground

Continuity

Yes

YHA238

AUTO AMP. CHECK Check power supply circuit for auto amp. with ignition switch ON. 1. Disconnect auto amp. harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. p 1 and body ground.

Auto amp. connector

Voltmeter terminal

! 1 p

YHA239

HA-51

@ Body ground

Voltage Approx. 12V

AUTO TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check (Cont’d) Check body ground circuit for auto amp. with ignition switch OFF. 1. Disconnect auto amp. harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. p 17 and body ground.

Auto amp. connector

Ohmmeter terminal

! YHA240

Continuity

@

17 p

Body ground

Yes

Diagnostic Procedure 1 SYMPTOM: Blower motor does not rotate at all. (Fan switch “AUTO”, “1”, “2”, “3”, “4”) ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.

Blower motor connector

KHA118

CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness terminal No. p 1 and body ground?

NG

E

Check 15A fuses (No. , at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK

Blower motor connector

H

Check circuit continuity between blower motor harness terminal No. and body ground.

NG 2 p

E

Reconnect blower motor harness connector.

OK H Continuity should exist.

KHA119

CHECK BLOWER MOTOR. NG H

Replace blower motor. Resistor connector H

KHA120

CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR. Do approx. 12 volts exist between resistor harness terminal No. p 5 and body ground? OK

Blower motor connector

Resistor connector H

NG

E

Disconnect blower motor and resistor harness connectors.

H

Note

Check circuit continuity between blower motor harness terminal No. 2 and resistor harness p terminal No. p 5 .

A p

(Go to next page.)

YHA244

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-52

TROUBLE DIAGNOSES Diagnostic Procedure 1 (Cont’d)

AUTO

A p

A/C Control panel connector

H

CHECK RESISTOR AFTER DISCONNECTING IT.

NG

E

Replace resistor.

OK H

CHECK FAN SWITCH. (Refer to Electrical Components Inspection.) (HA-78)

NG

E

Replace A/C control panel.

OK

NHA447

Note H Check circuit continuity between fan switch harness terminal No. p 2 , 8 , p 14 , p 20 and body ground. p Check body ground circuit for A/C control panel. (Refer to Main Power Supply and Ground Circuit Check, HA-51). OK H

Replace blower motor. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-53

AUTO

TROUBLE DIAGNOSES

Diagnostic Procedure 2: Models with relay type 1 SYMPTOM: Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3, or 4-speed only.)

LO relay connector

YHA245

CHECK POWER SUPPLY FOR A/C (LO) RELAY. Disconnect LO relay harness connector. Do approx. 12 volts exist between AUTO relay harness terminal No. p 1 and body ground?

NG

E

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK

LO relay connector H

Check circuit continuity between LO 2 and relay harness terminal No. p body ground. YHA246

NG

E

OK

CHECK FAN SWITCH (Refer to Electrical Components Inspection.) (HA-78) OK

NG H

Replace A/C control panel.

LO relay connector

H

Check circuit continuity between LO relay harness terminal No. p 2 and A/C control panel harness terminal No. 33 . p

YHA247

LO relay connector

Resistor connector

Note

Note

H

CHECK POWER SUPPLY FOR LO RELAY. Do approx. 12 volts exist between LO relay harness terminal No. p 3 and body ground? YHA248

NG

E

Check circuit continuity between resistor harness terminal No. p 8 and LO relay harness terminal No. p 3 .

OK H

A p

A/C control panel connector

(Go to next page.) LO relay connector

Continuity should exist when test leads are connected as shown; itshould not exist when test leads are reversed.

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

NHA448

HA-54

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 2: Models with relay type 1 (Cont’d) A p

LO relay connector

Note

H

Check circuit continuity between LO relay 5 and body harness terminal No. p ground. OK YHA250

H

CHECK LO RELAY AFTER DISCONNECTING IT.

HA-55

NG

E

Replace LO relay.

AUTO

TROUBLE DIAGNOSES

Diagnostic Procedure 2: Models with relay type 2 SYMPTOM: Blower motor does not rotate at all when the fan speed is in AUTO. (It operates in 1, 2, 3, or 4-speed only.)

YHA379

CHECK POWER SUPPLY FOR A/C (LO) RELAY. Disconnect LO relay harness connector. Do approx. 12 volts exist between AUTO relay harness terminal No. p 1 and body ground?

NG

E

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK H

Check circuit continuity between LO 2 and relay harness terminal No. p body ground. YHA380

NG

E

OK

CHECK FAN SWITCH (Refer to Electrical Components Inspection.) (HA-78) OK

NG H

Replace A/C control panel.

H

Note

Check circuit continuity between LO relay harness terminal No. p 2 and A/C control panel harness terminal No. 33 . p

YHA381

Note

H

CHECK POWER SUPPLY FOR LO RELAY. Do approx. 12 volts exist between LO relay harness terminal No. p 3 and body ground? YHA382

NG

E

Check circuit continuity between resistor harness terminal No. p 8 and LO relay harness terminal No. p 3 .

OK H

A p

(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

YHA389

HA-56

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 2: Models with relay type 2 (Cont’d) A p

Note Check circuit continuity between LO relay harness terminal No. p 5 and body ground. H

H

OK NG

CHECK LO RELAY AFTER DISCONNECTING IT.

E

Replace LO relay.

YHA384

Diagnostic Procedure 3: Models with relay type 1 Control panel connector

SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in HIGH or MED.)

Auto amp. connector

C/R *1

YHA262

Auto amp. connector

CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to HA-51.) Does blower motor fan speed change when you move PTC from 18°C (64°F) to 32°C (90°F)?

Note NG

E

OK

Control panel connector

CHECK PTC CIRCUIT BETWEEN CONTROL PANEL AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp ness terminal No. p 4 . OK

H YHA263

Note

H

Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp 5 . ness terminal No. p

CHECK SENSOR CIRCUIT. How to repair Ambient sensor circuit

Go to Diagnostic Procedure 11.

In-vehicle sensor circuit

Go to Diagnostic Procedure 12.

Reconnect control panel harness connector.

OK

OK F

H

CHECK A/C CONTROL PANEL. (Refer to HA-51.) NG H

Replace A/C Control panel. H

p A

(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-57

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 3: Models with relay type 1 (Cont’d) A p

Auto amp. connector H

Checking resistor Refer to pageHA-30. NHA301

CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 12 volts exist between auto amp. harness terminal No. p 15 , p 16 and body ground?

NG

E

Replace auto amp.

OK H

Blower motor connector

CHECK HIGH OR MED-HIGH, MEDLOW RELAY AFTER DISCONNECTING IT. (Refer to HA-78.)

HIGH relay connector

E

Replace HIGH relay or MED-HIGH, MED-LOW relay.

OK Note

H

NHA449

Does continuity exist between blower motor harness terminal No. p 2 and 3 ? HIGH relay terminal No. p Yes Note

H

Fan resistor connector

NG

MED-HIGH Relay connector

Does continuity exist between resistor harness terminal No. p 6 and MEDHIGH relay harness terminal No. p 3 ? Yes H

Replace auto amp.

YHA253

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-58

AUTO

TROUBLE DIAGNOSES

Diagnostic Procedure 3: Models with relay type 2 Control panel connector

SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in HIGH or MED.)

Auto amp. connector

C/R *1

YHA262

Auto amp. connector

CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to HA-51.) Does blower motor fan speed change when you move PTC from 18°C (64°F) to 32°C (90°F)?

Note NG

E

OK

Control panel connector

CHECK PTC CIRCUIT BETWEEN CONTROL PANEL AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp 4 . ness terminal No. p OK

H YHA263

Note

H

CHECK SENSOR CIRCUIT.

Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp ness terminal No. p 5 .

How to repair Ambient sensor circuit

Go to Diagnostic Procedure 11.

In-vehicle sensor circuit

Go to Diagnostic Procedure 12.

Reconnect control panel harness connector.

OK

OK F

H

CHECK A/C CONTROL PANEL. (Refer to HA-51.) NG H

Replace A/C Control panel. H

p A

(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-59

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 3: Models with relay type 2 (Cont’d) A p

Auto amp. connector H

Checking resistor Refer to pageHA-30. NHA301

CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 12 volts exist between auto amp. harness terminal No. p 15 , p 16 and body ground?

NG

E

Replace auto amp.

OK H

Blower motor connector

CHECK HIGH OR MED-HIGH, MEDLOW RELAY AFTER DISCONNECTING IT. (Refer to HA-78.)

HIGH relay connector

NG

E

Replace HIGH relay or MED-HIGH, MED-LOW relay.

OK Note

H

NHA449

Does continuity exist between blower motor harness terminal No. p 2 and 3 ? HIGH relay terminal No. p Yes Note

H

Does continuity exist between resistor harness terminal No. p 6 and MEDHIGH relay harness terminal No. p 3 ? Yes H

Replace auto amp.

YHA385

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-60

AUTO

TROUBLE DIAGNOSES

Diagnostic Procedure 4: Models with relay type 1 Auto amp. connector

AUTO amp. connector

YHA254

SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LOW.) CHECK THERMAL TRANSMITTER. Disconnect auto amp. harness connector. Is resistance between auto amplifier terminal No. p 10 and p 5 lower than approx. 940Ω?

OK

E

NG

CHECK POWER SUPPLY FOR LOW RELAY. Disconnect low relay. Do approx. 12 volts exist between low relay harness terminal No. p 1 and body ground? OK

NG

H

CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA-77) YHA390 H

H

Reconnect low relay.

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

A/C control panel connector

H

NHA450

NG

CHECK A/C CONTROL PANEL Do approx. 0.5V exist between A/C control panel terminal p 35 and body ground when you select AUTO position?

E

Replace A/C control panel.

OK Auto amp. connector

A/C control panel connector

Note

H

Check circuit continuity between A/C control panel harness terminal p 35 and 11 . auto amp. harness terminal p OK H

YHA259

CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 0 volts exist between low relay harness terminal No. p 2 and body ground when you move PTC from 18°C (64°F) to 32°C (90°F)? H

NG

E

Replace low relay.

OK

A p

(Go to next page) YHA391

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-61

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 4: Models with relay type 1 (Cont’d) A p

Auto amp. connector H

YHA257

CHECK POWER SUPPLY FOR AUTO AMP. Disconnect auto amp. harness connector. Do approx. 12 volts exist between auto amp. harness terminal No. p 1 and body ground?

NG

E

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK Note

H

Auto amp. connector

CHECK BODY GROUND CIRCUIT FOR AUTO AMP. Does continuity exist between auto amp. harness terminal No. p 17 and body ground? OK YHA258

H

Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-62

AUTO

TROUBLE DIAGNOSES

Diagnostic Procedure 4: Models with relay type 2 Auto amp. connector

AUTO amp. connector

YHA254

SYMPTOM: Blower motor fan speed does not change when fan speed is in AUTO. (Fan speed is fixed in LOW.) CHECK THERMAL TRANSMITTER. Disconnect auto amp. harness connector. Is resistance between auto amplifier terminal No. p 10 and p 5 lower than approx. 940Ω?

OK

E

NG

CHECK POWER SUPPLY FOR LOW RELAY. Disconnect low relay. Do approx. 12 volts exist between low relay harness terminal No. p 1 and body ground? OK

NG

H

CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA-77) YHA386 H

H

Reconnect low relay.

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

A/C control panel connector

H

NHA450

NG

CHECK A/C CONTROL PANEL Do approx. 0.5V exist between A/C control panel terminal p 35 and body ground when you select AUTO position?

E

Replace A/C control panel.

OK Auto amp. connector

A/C control panel connector

Note

H

Check circuit continuity between A/C control panel harness terminal p 35 and 11 . auto amp. harness terminal p OK H

YHA259

CHECK AUTO AMP. Connect checking resistor. (Refer to HA-30.) Do approx. 0 volts exist between low relay harness terminal No. p 2 and body ground when you move PTC from 18°C (64°F) to 32°C (90°F)? H

NG

E

Replace low relay.

OK

A p

(Go to next page) YHA387

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-63

AUTO TROUBLE DIAGNOSES Diagnostic Procedure 4: Models with relay type 2 (Cont’d) A p

Auto amp. connector H

YHA257

CHECK POWER SUPPLY FOR AUTO AMP. Disconnect auto amp. harness connector. Do approx. 12 volts exist between auto amp. harness terminal No. p 1 and body ground?

NG

E

Check 10A fuse (No.

26 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK Note

H

Auto amp. connector

CHECK BODY GROUND CIRCUIT FOR AUTO AMP. Does continuity exist between auto amp. harness terminal No. p 17 and body ground? OK YHA258

H

Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-64

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 5

SYMPTOM: Starting fan speed control does not operate. A/C control panel connector

CHECK THERMAL TRANSMITTER CIRCUIT. Go to Diagnostic Procedure 14. (HA77)

NG

E

Replace engine thermal transmitter.

E

Replace A/C control panel

OK NHA451

Auto amp. connector

A/C control panel connector

H

CHECK A/C CONTROL PANEL OPERATION Do approx. 12V exist between A/C control panel harness terminal p 22 and body ground when water temp. is below 56°C (133°F)?

NG

NG Note

H

YHA259

Disconnect auto amp. and A/C control panel harness connector. Check circuit continuity between auto amp. harness terminal No. p 11 and A/C control panel harness terminal No. 35 . p OK H

Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-65

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 6

SYMPTOM: There is too much difference between setting temp. on PTC and in-vehicle temperature. ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.

Air mix door motor connector

C/R *2

Checking resistor Refer to pageHA-30.

RHA963G

CHECK PBR. Connect checking resistor. (Refer to HA-30.) Do approx. 5 volts exist between air mix door motor harness terminal No. 4 and p 3 when PTC is set at p 25°C (77°F)?

NG

E

CHECK PTC. (Refer to HA-84.) OK H

Replace A/C control panel.

OK H

A p

(Go to next page.)

NG

H

CHECK PBR. Refer to Inspection of Sensor. OK

H

Replace auto amp.

NG

H

CHECK AIR MIX DOOR MECHANISM. Refer to Control Linkage Adjustment. (Refer to HA-83.) OK

NG H

Repair or adjust. H

Replace AIR MIX MOTOR.

HA-66

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 6 (Cont’d) A p

CONNECT

H

Auto amp. connector M421

CHECK IN-VEHICLE SENSOR AND AMBIENT SENSOR. (Refer to Control System Input Components.) (HA-85, 86)

NG

E

Replace in-vehicle sensor or ambient sensor.

E

Replace sunload sensor or auto amp.

OK H

CHECK SUNLOAD SENSOR. Go to Diagnostic Procedure 13. (HA76) Auto amp. connector M421

NG

OK H

RHA037H

CHECK AUTO AMP. OPERATION. Do approx. 0.5 volts exist between auto amp. harness terminal No. p 9 and body ground when A/C switch is ON? Do approx. 0 volts exist between auto amp. harness terminal No. p 9 and body ground when A/C switch is OFF?

NG

E

CHECK A/C CONTROL PANEL OPERATION. Do approx. 0.5 volts exist between A/C control panel connector terminal No. p 29 and body ground when A/C switch is ON? OK

OK

NG H

Replace A/C control panel

H

Replace auto amp.

H

Note

Check circuit continuity between A/C control panel harness terminal 29 and Auto amp. harp ness terminal p 9

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-67

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 7 Control panel connector

SYMPTOM: Air mix door motor does not operate normally. ● Perform PRELIMINARY CHECK 2 before referring to the following flow chart.

Auto amp. connector

C/R *2

YHA262

CHECK AUTO AMP. AND PTC. Connect checking resistor. (Refer to page HA-30.) Does air outlet temperature change when you move PTC from 20°C (68°F) to 30°C (86°F)?

NG

E

OK Auto amp. connector

Control panel connector

Note CHECK PTC CIRCUIT BETWEEN PTC AND AUTO AMP. Disconnect control panel and auto amp. harness connectors. Check circuit continuity between control panel harness terminal No. 21 and auto amp. harp ness terminal No. p 4 . OK

H

Check circuit continuity between control panel harness terminal No. 25 and auto amp. harp ness terminal No. p 5 .

CHECK SENSOR CIRCUIT. How to repair YHA263

Ambient sensor circuit

Go to Diagnostic Procedure 11.

In-vehicle sensor circuit

Go to Diagnostic Procedure 12.

Air mix door motor connector

Note

H

H

OK

NG

CHECK PTC. (Refer to HA-84.)

E

Replace A/C control panel.

OK H

CHECK FOR OUTPUT OF AUTO AMP. Connect checking resistor. Do approx. 10.5 volts exist between air mix door motor harness terminals No. 4 and p 1 when you move PTC p from 18°C (64°F) to 32°C (90°F) or when you move PTC from 32°C (90°F) to 18°C (64°F)? Air mix door operation NHA303

Terminal No. 1 p

4 p

Cold , Hot

!

@

Hot , Cold

@

!

Stop

—

—

Voltage Approx. 10.5V 0V

NG

E

Disconnect auto amp. and air mix door motor harness connectors.

Note

H

Check circuit continuity between auto amp. harness terminal No. p 12 (p 13 ) and air mix door motor harness terminal No. p 1 (p 4 ). OK H

Replace auto amp. H

OK

Replace air mix door motor. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-68

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 9

SYMPTOM: Intake door does not change. ● Perform PRELIMINARY CHECK 1 and Main Power Supply and Ground Circuit Check before referring to the following flow chart.

Intake door motor connector

YHA261

CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR. Disconnect intake door motor harness connector. Do approx. 12 volts exist between intake door motor harness terminal No. 1 and body ground? p

NG

E

Check 10A fuses (No. 20 ) at fuse block. (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

OK Intake door motor connector

Continuity should exist when test leads are connected as shown; itshould not exist when test leads are reversed.

Intake door motor connector

H

CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR. Does continuity exist between intake door motor harness terminal No. p 3 and body ground when REC switch is ON? Does continuity exist between intake door motor harness terminal No. p 4 and body ground when REC switch is OFF? OK

NG

E

Disconnect control panel harness connector.

Note

H

Check circuit continuity between control panel harness terminal No. 4 (p 6 ) and intake p door motor harness terminal No. p 3 (p 4 )? OK

H

Replace intake door motor. NHA452

Control panel connector

Intake door motor connector

H

Replace A/C control panel.

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

YHA265

HA-69

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 10

SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. Compressure connector

YHA266

Yes Check the following. CHECK POWER SUPPLY FOR E COMPRESSOR. ● Magnet clutch coil Disconnect compressor harness conNG nector. H Do approx. 12 volts exist between Replace magnet clutch. compressor harness terminal No. Refer to HA-111. 1 and body ground? p No

Compressure connector

Note H Check circuit continuity between A/C NG relay harness terminal No. p 3 and compressor harness terminal No. 1 . p Continuity should exist. If OK, check harness for short.

A/C relay connector

E

Check the following. ● Thermal protector (GA, diesel engine)

OK YHA267

H

CHECK POWER SUPPLY FOR A/C RELAY. Do approx. 12 volts exist between A/C relay harness terminal No. p 5 and body ground?

A/C relay connector

No

E

Yes H

YHA268

CHECK POWER SUPPLY FOR A/C RELAY. Do approx. 12 volts exist between A/C relay harness terminal No. p 2 and body ground?

Yes

E

No H

CHECK A/C RELAY AFTER DISCONNECTING IT. Refer to HA-78.

A/C relay connector

NG

E

Check power supply circuit and 10A fuse (No. 20 ), located in the fuse block). (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.)

Check power supply circuit and 10A fuse (No. 20 ), located in the fuse block). (Refer to “POWER SUPPLY ROUTING” in EL section and Wiring Diagram.) Replace A/C relay.

OK H

Reconnect A/C relay. YHA269

For Diesel engine

p

(Go to HA-71)

p

(Go to HA-73)

E A

For SR engine or QG engine

EC

Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-70

TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d)

AUTO

A p

H

ECM connector

CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness terminal No. 204 and body ground?

No

E

Disconnect A/C relay. Disconnect ECM harness connector.

Yes Note H CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY HARNESS TERMINAL NO. p 1 AND ECM HARNESS TERMINAL NO. 204 . Continuity should exist. If OK, check harness for short.

NHA454

A/C relay connector

ECM connector

H

p B

NHA455

(Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-71

TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d)

AUTO

B p

ECM connector

H

No

CHECK VOLTAGE FOR ECM. Do approx. 12 volts exist between ECM harness terminal No. 403 and body ground? H

NHA456

E

CHECK ECM. Refer to EC section.

Yes

Disconnect ECM harness connector. Disconnect triple-pressure switch harness connector. Yes H

ECM connector

Triplepressure switch connector

CHECK CIRCUIT CONTINUITY BETWEEN ECM HARNESS TERMINAL NO. 403 AND TRIPLE-PRESSURE SWITCH HARNESS TERMINAL NO. p 4 . Continuity should exist. If OK, check harness for short. H

NHA457

NG E Replace triple-pressure

CHECK TRIPLE-PRESSURE SWITCH. Refer to HA-79. H

switch.

OK

Disconnect thermo control amp. switch harness connector. Triple-pressure switch connector

Thermo control amp.

Note

H

YHA280

CHECK CIRCUIT CONTINUITY BETWEEN TRIPLE-PRESSURE SWITCH HARNESS TERMINAL NO. p 1 AND THERMO CONTROL AMP. SWITCH HARNESS TERMINAL NO. p 3 . Continuity should exist. If OK, check harness for short. H

Thermo control amp.

OK

CHECK THERMO CONTROL AMP. Refer to HA-80.

Control panel connector

YHA275

Note H OK Check circuit continuity between control CHECK FOR A/C CONE 10 and thermo panel harness terminal No. p TROL PANEL OPERATION. control amp. No. p 2 . Does approx. 0.5V exist between A/C control panel harness terminal No. 10 and body ground? p OK Check ECM

A/C control panel connector

F

NG H

Replace A/C control panel

Note: If the result is NG or No after checking circuit continuity, repair harness or connector. NHA453

HA-72

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d) C p

ECM connector H

CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness terminal No.p 23 and body ground?

No

E

Disconnect A/C relay. Disconnect ECM harness connector.

Yes YHA281

A/C relay connector

Note CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY HARNESS TERMINAL NO. p 1 AND ECM HARNESS TERMINAL NO. p 23 . Continuity should exist. If OK, check harness for short. H

ECM connector

H YHA282

CHECK VOLTAGE FOR ECM. Do approx. 12 volts exist between ECM harness terminal No. p 44 and body ground?

ECM connector

No

E

CHECK ECM. Refer to EC section.

E

Replace pressure sensor.

Yes H

Disconnect ECM harness connector. Disconnect refrigerant pressure sensor harness connector. Yes Note

H NHA458

ECM connector Refrigerant pressure sensor connector

CHECK CIRCUIT CONTINUITY BETWEEN ECM HARNESS TERMINAL NO. p 74 AND PRESSURE SENSOR HARNESS TERMINAL NO. p 2 . Continuity should exist. If OK, check harness for short. H

NG

CHECK PRESSURE SENSOR. Refer to HA-80. H

YHA273

D p

OK

(Go to next page.)

HA-73

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 10 (Cont’d) D p

H

A/C control panel connector

CHECK FOR A/C CONTROL PANEL OPERATION. Does approx. 0.5V exist between A/C control panel harness terminal No. p 10 and body ground?

NG

E

Replace A/C control panel.

OK NHA453

Thermo control amp.

H Note Check circuit continuity between control panel harness terminal No. p 10 and thermo control amp. No. p 2 .

Control panel connector

H

OK

Check ECM.

Note: If the result is NG or No after checking circuit continuity, repair harness or connector. YHA275

Diagnostic Procedure 11 SYMPTOM: Ambient sensor circuit is open or shorted. Ambient sensor connector

YHA283

CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. Disconnect ambient sensor harness connector. Do approx. 5 volts exist between ambient sensor harness terminal No. p 1 and body ground?

NG E

Ambient sensor connector

Check circuit continuity between auto amp. harness terminal No. p 8 and ambient sensor harness terminal No. p 1 , and between auto amp. harness terminal No. 8 and body ground. p

H

H

Disconnect auto amp. harness connector.

Ambient sensor connector

Replace auto amp.

Check circuit continuity between ambient sensor harness terminal No. p 2 and auto amp. harness terminal No. p 5 . H

Auto amp. connector

OK

Note

H

YHA284

Note

H

OK

Auto amp. connector

Disconnect auto amp. harness connector.

OK

CHECK AMBIENT SENSOR. (Refer to HA-86.) H

NG E

Replace ambient sensor.

OK

Replace auto amp.

Note: If the result is NG or No after checking circuit continuity, repair harness or connector. YHA285

HA-74

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 12

SYMPTOM: In-vehicle sensor circuit is open or shorted. In-vehicle sensor connector

YHA286

CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. Disconnect in-vehicle sensor harness connector. Do approx. 5 volts exist between invehicle sensor harness terminal No. 1 and body ground? p

NG

E

Disconnect auto amp. harness connector.

OK

Auto amp. connector

In-vehicle sensor connector

H

Note

H

Check circuit continuity between auto amp. harness terminal No. p 7 and in-vehicle sensor harness terminal No. 1 , and between auto p amp. harness terminal No. p 7 and body ground.

Disconnect auto amp. harness connector.

YHA287

OK Auto amp. connector

In-vehicle sensor connector

Note

H

H

Check circuit continuity between invehicle sensor harness terminal No. 2 and auto amp. harness terminal p 8 . No. p

Replace auto amp.

OK H YHA288

CHECK IN-VEHICLE SENSOR. (Refer to HA-85.)

NG

E

Replace in-vehicle sensor.

OK H

Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-75

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 13

SYMPTOM: Sunload sensor circuit is open or shorted. Sunload sensor connector

YHA289

CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. Disconnect sunload sensor harness connector. Do approx. 5 volts exist between sunload sensor harness terminal No. p 1 and body ground?

NG

E

Note

H

Check circuit continuity between auto amp. harness terminal No. p 6 and sunload sensor harness terminal No. p 1 and between auto amp. harness terminal No. 6 and body ground. p

OK Auto amp. connector

Disconnect auto amp. harness connector.

Sunload sensor connector

OK H

H

Disconnect auto amp. harness connector.

Replace auto amp.

YHA290

Note

H

Auto amp. connector

Sunload sensor connector

Check circuit continuity between sunload sensor harness terminal No. p 2 and auto amp. harness terminal No. 5 . p OK H

CHECK SUNLOAD SENSOR. (Refer to HA-86.) YHA291

NG

E

Replace sunload sensor.

OK H

Replace auto amp. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-76

AUTO

TROUBLE DIAGNOSES Diagnostic Procedure 14

SYMPTOM: Thermal transmitter circuit is open or shorted. Note Thermal transmitter connector

YHA292

CHECK THERMAL TRANSMITTER CIRCUIT. Disconnect thermal transmitter harness connector. Do approx. 12 volts exist between thermal transmitter harness terminal No. 1 and body ground? p

NG

E

Check circuit continuity between thermal transmitter harness terminal No. p 1 and control panel harness terminal No. p 24 .

OK H

Replace control panel Control panel connector

Thermal transmitter connector

H

Disconnect control panel harness connector. H

YHA293

CHECK THERMAL TRANSMITTER. (Refer to “THERMAL TRANSMITTER CHECK” in EL section.)

NG

E

Replace thermal transmitter.

OK H

Replace control panel Note: If the result is NG or No after checking circuit continuity, repair harness or connector.

HA-77

AUTO

TROUBLE DIAGNOSES Electrical Components Inspection FAN SWITCH Check voltage terminals at each switch position.

A/C control panel

FUNCTION

NHA291

A/C CONTROL PANEL TERMINAL

SWITCH POSITION LOW OFF

MEDIUM MEDIUM LOW HIGH

I

I

I I

II

HIGH

II

II

OFF

—

—

—

—

—

—

FAN RELAY LO

33

12V

<0.5V

<0.5V

<0.5V

<0.5V

FAN RELAY MLO

32

12V

12V

<0.5V

<0.5V

<0.5V

FAN RELAY MHI

31

12V

12V

12V

<0.5V

<0.5V

FAN RELAY HI

30

12V

12V

12V

12V

<0.5V

A/C SWITCH Check voltage terminals at each switch position. Switch condition

Terminal No. 10 p

A/C

29 p

ON

< 0.5V

< 0.5V

OFF

0

0

A/C control panel

NHA292

A/C, LOW, MED-LOW, MED-HIGH and HIGH RELAYS Check continuity between terminal Nos.

3 p

and

5 . p

Conditions

Continuity

1 p

12V direct current supply between terminal Nos. and p 2

Yes

No current supply

No

If NG, replace relay. YHA389

HA-78

AUTO TROUBLE DIAGNOSES Electrical Components Inspection (Cont’d) .

TRIPLE-PRESSURE SWITCH (WITH DIESEL ENGINE) Triple-pressure switch

Terminals

RHA364G

Lowpressure side

Mediumpressure side*

Highpressure side

1 - p 4 p

2 - p 3 p

1 - p 4 p

High-pressure side line pressure kPa (bar, kg/cm2, psi)

Operation

Continuity

Increasing to 152.0 - 201.0 (1.520 - 2.010, 1.55 - 2.05, 22.0 - 29.2)

ON

Exists.

Decreasing to 152.0 - 201.0 (1.520 - 2.010, 1.55 - 2.05, 22.0 - 29.2)

OFF

Does not exist.

Increasing to 1,422 - 1,618 (14.22 - 16.18, 14.5 - 16.5, 206 - 235)

ON

Exists.

Decreasing to 1,128 - 1,422 (11.28 - 14.22, 11.5 - 14.5, 164 - 206)

OFF

Does not exist.

Decreasing to 2,059 - 2,256 (20.6 - 22.6, 21 - 23, 299 - 327)

ON

Exists.

Increasing to 2,648 - 2,844 (26.5 - 28.4, 27 - 29, 384 - 412)

OFF

Does not exist.

* For cooling fan motor operation

HA-79

AUTO TROUBLE DIAGNOSES Electrical Components Inspection (Cont’d)

PRESSURE SENSOR V out (V) Vcc = 5.0 (VDC)

Dual-pressure switch (3.882) GND V out V cc

Pg

(0.362)

0.278 (1.8)

Kpa (kgf/cm2G) KHA121

2.65 (26)

THERMO CONTROL AMP. Evaporator outlet air temperature °C (°F)

Thermo amp. operation

Tester

Decreasing to 0.1 - 0.9 (32 - 34)

Turn OFF

Approx. 12V

Increasing to 2.5 - 3.5 (37 - 38)

Turn ON

Approx. 0V

RHA329F

Control Panel System This control panel system operates the intake door motor to activate their corresponding doors.

SWITCHES AND THEIR CONTROL FUNCTIONS Knob/Switch position A/C

Compressor

q

ON*1

Air outlet Intake air Knob/Switch A/C

q

VENT

Mode

q

B/L q

FOOT q

F/D q

DEF q

*1: Compressor is operated by thermo control amp. (With diesel engine) Compressor is operated by ECM (with SR engine and QG engine).

HA-80

FRE REC

ON*1

TROUBLE DIAGNOSES Control Panel System (Cont’d)

AUTO

INTAKE DOOR MOTOR The intake door motor is installed on the intake unit. When the door position is determined by pushing the “REC” switch on the control panel, the motor rotates and the air inlet is changed.

NHA293

Ignition switch ON

Intake door motor

To A/C control

YHA294

Removal and Installation Refer to “INSTRUMENT PANEL” in BT section for details. Snap ring

Mode cable

NOTE: When removing the control panel, the Mode control cable should be disconnected from the control panel rather than from the heater. Removal of the mode cable will result in breakage of the ferrule retaining clips. On reassembly, the cable is retained by a snap ring (Part number: 9-22504-1) which is pushed into a slot in the control base plate which aligns with a groove in the cable sleeve.

Control panel KHA125

HA-81

TROUBLE DIAGNOSES

AUTO

Control Linkage Adjustment MODE CONTROL CABLE

.

ZHA176A

1. For RHD models, turn the mode control knob to the VENT position. For LHD models, turn the mode control knob to the DEF position. 2. For RHD models, set the side link in the VENT position by hand. For LHD models, set the side link in the DEF position by hand. 3. Pull on the cable cover in the direction of the arrow, then clamp it. After positioning control cable, check that it operates correctly.

RHA630E

WATER COCK CONTROL ROD When adjusting water cock control rod, first disconnect temperature control cable from air mix door lever and then adjust control rod. Reconnect temperature control cable and readjust it. (Refer to TEMPERATURE CONTROL CABLE.) 1. Push air mix door lever in direction of arrow. 2. Pull control rod of water cock in direction of arrow so as to make clearance of about 2 mm (0.08 in) between ends of rod and link lever and connect the rod to door lever. After connecting control rod, check it operates correctly. ●

SHA522E

HA-82

TROUBLE DIAGNOSES Control Linkage Adjustment (Cont’d)

AUTO

AIR MIX DOOR

Heater unit Air mix door link

Air mix door lever Air mix door motor

KHA127

1. Install air mix door motor on heater unit. Ensure that the air mix door motor lever is fitted into slit portion of air mix door link. 2. Connect the air mix door motor harness connector. 3. Turn ignition switch to “ON” position. 4. Check that air mix door operates properly when PTC is moved from 18 to 32°C (64 to 90°F). After positioning control cable, check that it operates correctly.

FRESH VENT CONTROL CABLE 1. Turn the fresh vent control knob to the shut position. 2. Set the fresh vent door lever in shut position. 3. Adjust the position of the cable cover for proper operation, then secure to the clamps. After positioning control cables, check that it operates correctly.

Clamp

Pull

Clamp

Cable cover KHA126

INTAKE DOOR MOTOR 1. Install intake door motor on intake unit. Ensure that the intake door motor lever is fitted into the slit portion of intake door link. 2. Connect the intake door motor harness connector. 3. Turn ignition switch to “ON” position. 4. Check that intake door operates properly when REC switch is turned ON and OFF. ZHA178A

HA-83

AUTO

SYSTEM DESCRIPTION Overview of Control System

The control system consists of a) input sensors and switches, b) the automatic amplifier (microcomputer), and c) outputs. The relationship of these components is shown in the diagram below.

A/C control panel PTC (Potentio temperature Control) A/C switch Autoswitch Fan switch

Ambient sensor

Automatic amplifier (Micro-computer) Air mix door motor

Air mix door

In-vehicle sensor PBR (Potentio Balance Resistor)built-into air mix door motor

sunload sensor LOW, MED, HIGH and AUTO

Blower motor

Thermal transmitter

YHA295

Control System Input Components POTENTIO TEMPERATURE CONTROL (PTC) The PTC is built into the control panel. It can be set at an interval of 1°C in the 18°C to 32°C temperature range by pushing the temperature button. The set temperature is digitally displayed.

Temperature button NHA294

Measure voltage between auto amp. terminal ground. Auto amp. connector

NHA315

HA-84

4 p

and body

AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d)

Output voltage

PTC Output voltage

Set temperature

(°C)

KHA128

IN-VEHICLE SENSOR The in-vehicle sensor is attached to the right side of the control unit. It converts variations in the temperature of the compartment air drawn in by the aspirator into a resistance value, which is then input into the auto amplifier. In-vehicle sensor

NHA295

After disconnecting in-vehicle sensor harness connector, measure resistance between terminals p 1 and p 2 at sensor harness side, using the table below. In-vehicle sensor

Temperature °C (°F)

Resistance kΩ

0 (32)

6.0

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

In-vehicle sensor

NHA287

Aspirator Aspirator duct Aspirator

The aspirator is located in front of heater unit. It produces vacuum pressure due to air discharged from the heater unit, continuously taking compartment air in the aspirator.

NHA312

HA-85

AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d) Aspirator

Aspirator duct

Heater unit case

RHA979G

AMBIENT SENSOR The ambient sensor is located on the hood lock stay. It detects the ambient temperature and converts it into a resistance value, which is then input into the auto amplifier.

Ambient sensor

NHA313

After disconnecting ambient sensor harness connector, measure resistance between terminals p 1 and p 2 at sensor harness side, using the table below.

Ambient sensor harness connector

Temperature °C (°F)

Resistance kΩ

−20 (−4)

9.98

−10 (14)

5.57

0 (32)

3.26

10 (50)

1.98

20 (68)

1.25

25 (77)

1.00

30 (86)

0.81

40 (104)

0.54

Ambient sensor

NHA288

SUNLOAD SENSOR The sunload sensor is located on the center defroster grille. It detects sunload entering through the windshield by means of a photo diode and converts it into a current value which is then input to the auto amplifier.

Sunload sensor

NHA314

HA-86

AUTO SYSTEM DESCRIPTION Control System Input Components (Cont’d) Measure voltage between terminals p 5 and p 6 at auto air conditioner harness side, using the table below.

Auto amplifier

Auto amp. connector Auto amp. connector

●

Input current mA

Output voltage V

0

5.00

0.1

4.09

0.2

3.18

0.3

2.27

0.4

1.36

0.5

0.45

When checking sunload sensor, select a place where sun shines directly on it.

NHA289

A/C RELAY .

The A/C relay is located on the left side of the engine room. When the A/C remain and fan switch are ON, the A/C relay operates and transmits A/C operation signals to ECM.

A/C Relay

NHA298

Control System Auto Amplifier (Auto amp.) The auto amplifier has a built-in microcomputer which processes the information sent from the various sensors needed for air conditioner operation. The air mix door motor and blower motor are then controlled. Signals from the various switches and the Potentio Temperature Control (PTC) are directly entered into the auto amplifier.

Auto amplifier

RHA024H

SUNLOAD INPUT PROCESS The auto amp. also includes a processing circuit which “averages” the variations in detected sunload over a period of time. This prevents drastic swings in the ATC system operation due to small or quick variations in detected sunload. For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the ATC

HA-87

AUTO SYSTEM DESCRIPTION Control System Auto Amplifier (Auto amp.) (Cont’d) system operation. On the other hand, shortly after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly.

SUNLOAD COMPENSATION The auto amplifier compensates for sunload by altering the air mix door position and air flow volume according to the amount of sunload detected by the sunload sensor. When the amount of sunload is great, the air mix door is moved toward the “COLD” side. Along with this air mix door movement, air flow volume will also be changed.

Auto amplifier A/C control panel PTC

In-vehicle sensor

Air mix door position arithmetic circuit

Air mix door motor

Air flow volume arithmetic circuit

LOW, MED, HIGH and AUTO relays

Ambient sensor Sunload compensation Sunload sensor

Air mix door position compensation amount

YHA296

Sunload kW (kcal/h, BTU/h)/m2 [kW (kcal/h,BTU/h)/sq ft]

0.768 (660, 2,619) [0.0713 (61.31, 243.3)]

Sunload compensation specifications SHA493CA

HA-88

AUTO SYSTEM DESCRIPTION Control System Auto Amplifier (Auto amp.) (Cont’d)

A/C SWITCH COMPENSATION The auto amplifier alters the air mix door position and air flow volume according to a signal emitted from the A/C switch. When the A/C switch is “ON”, the auto amplifier compensates for the PBR’s input signal and moves the air mix door toward the “HOT” side. Auto amplifier A/C control panel PTC

In-vehicle sensor Air mix door position arithmetic circuit Ambient sensor Air mix door motor

Output signal process

Sunload sensor

A/C control panel A/C switch

PBR

Sunload compensation

YHA297

Air mix door opening ratio

(%) 100

15

0

0

100

(%)

Air mix door position arithmetic value A/C switchcompensation specifications KHA115

HA-89

SYSTEM DESCRIPTION

AUTO

Control System Output Components AIR MIX DOOR CONTROL (Automatic temperature control) Component parts Air 1) 2) 3) 4) 5) 6)

mix door control system components are: Auto amplifier Ambient sensor In-vehicle sensor Sunload sensor Air mix door motor (PBR) A/C switch

System operation The air mix door is automatically controlled so that in-vehicle temperature is maintained to the set temperature. The temperature set by the PTC (Potentio Temperature Control) and the temperature detected by the in-vehicle sensor and ambient sensor are compensated by the sunload sensor signal. The auto amplifier then determines the air mix door position. The air mix door position detected by the PBR is compensated by the ON-OFF operation of the A/C switch. The air mix door position determined by the auto amplifier is compared with that detected by the PBR. The auto amplifier then transmits the signal to the air mix door motor in order to activate it.

Auto amplifier

Constant voltage transformation PTC In-vehicle sensor

Ambient sensor PBR

Air mix door position arithmetic circuit

Air mix door motor

Sunload compensation

sunload sensor Air mix door position detection

A/C switch

A/C switch compensation

KHA116

HA-90

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) Air mix door control specifications

PTC: 25°C (77°F) Condition

Fan switch Auto Withoutsunload

Ambient temperature °C (°F) 2.4

Voltage (V)

2.3

-20 (-4) -10 (-4)

0 (32) 2.2 A/C switch OFF 10(50) 2.1 20 (68) A/C switch ON 25 (77)

2.0

30(86)

1.9 54.5 Air mix door opening angle 0.5

1.0

1.5 2.0 2.5 PBRresistance (kΩ)

40 (104) (59)

(68) (77) (86) In vehicle temperature °C (°F)

(95)

(104)

3.0

SHA497CB

SENSOR INPUT PROCESS Auto amplifier

The auto amplifier detects the voltage produced by each sensor, the PBR and fixed resistor. The fixed resistor is built into the auto amplifier. 12-volt power voltage is first converted to approximately 5 volts by the constant voltage circuit where it is then applied to the ground line of the auto amplifier via the fixed resistor and the sensor. In this manner, the auto amplifier monitors the voltages of the fixed resistor, each sensor and the PBR to determine sensor input.

Constant-voltage circuit Fixed resistor

Detection of sensor voltage Each sensor

RHA790A

HA-91

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)

OPERATION OF AIR MIX DOOR MOTOR ●

Auto amp. Comparator (1) Air mix door position arithmetic circuit

Air mix door motor

Example p 1 When the temperature in the vehicle is lower than the set temperature. When the temperature in the vehicle is low, in-vehicle sensor resistance is great and the input voltage to the auto amplifier becomes great. As a result, the voltage from the air mix door position arithmetic circuit also becomes great. When this voltage is greater than the voltage from the PBR, comparator (1), Tr p 1 and Tr p 4 turn ON. 12 becomes ! and terminal No. Accordingly terminal No. p 13 becomes @. The air mix door motor rotates clockwise and p the air mix door moves toward the “HOT” side.

PBR Comparator (2)

RHA514DB

As the air mix door moves toward the “HOT” side, the voltage from the PBR becomes greater and consequently becomes equal to that from the air mix door position arithmetic circuit. As a result, comparator (1) turns OFF and the air mix door motor stops.

Auto amp. Comparator (1) Air mix door position arithmetic circuit

Air mix door motor

PBR Comparator (2)

SHA568CB

HA-92

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) ● Example p 2

Auto amp. Comparator (1) Air mix door position arithmetic circuit

Air mix door motor

When the temperature in the vehicle is higher than the set temperature. When the temperature in the vehicle is high, in-vehicle sensor resistance is small and the input voltage to the auto amplifier becomes small. As a result, the voltage from the air mix door position arithmetic circuit also becomes small. When this voltage is smaller than the voltage from the PBR, comparator (2), Tr p 2 and Tr p 3 turn ON. 13 becomes ! and terminal No. Accordingly terminal No. p 12 becomes @. The air mix door motor rotates counterclockp wise and the air mix door moves toward the “COLD” side.

PBR Comparator (2)

SHA569CB

As the air mix door moves toward the “COLD” side, the voltage from the PBR becomes smaller and consequently becomes equal to that from the air mix door position arithmetic circuit. As a result, comparator (2) turns OFF and the air mix door motor stops.

Auto amp. Comparator (1) Air mix door position arithmetic circuit

Air mix door motor

PBR Comparator (2)

SHA570CB

AIR MIX DOOR MOTOR

Heater unit Air mix door link

The air mix door motor is attached to the heater unit. It rotates so that the air mix door is opened to a position set by the auto amplifier. Motor rotation is conveyed through a shaft. The air mix door position is then fed back to the auto amplifier by the PBR built into the air mix door motor.

Air mix door lever Air mix door motor

KHA127

HA-93

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) Air mix door motor connector M413

(Cold side)

(HOT side)

2

1

Air mix door operation

Direction of lever movement

!

@

COLD , HOT

Clockwise (Toward passenger compartment)

—

—

STOP

STOP

@

!

HOT , COLD

Counterclockwise (Toward engine compartment)

PBR RHA026H

Characteristic PBR

Resistance of PBR (Ω) 4 andp 3 ) (resistance between terminal p

.

3.0

2.5

2.0

1.5

1.0

0.5

60° COLD

Air mix door opening angle

HOT KHA129

PBR Measure voltage between terminals ness side.

Air mix door motor

and

4 p

at vehicle har-

NHA311

Ignition switch: ON

5.0

●

4.0 Voltage (V)

3 p

Ensure tester pointer deflects smoothly when PTC is moved from 18°C (64°F) to 32°C (90°F) and vice versa.

3.0 2.0 1.0 0 Full cold

Full hot

Air mix door opening angle PBR RHA607AA specification

HA-94

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)

FAN SPEED CONTROL Component parts Fan speed control system components are: 1) Auto amplifier 2) In-vehicle sensor 3) Ambient sensor 4) Sunload sensor 5) A/C switch relay 6) A/C switch 7) Fan switch 8) Blower motor 9) Resistance 10) HI, MH, ML and LO relays

System operation Blower fan speed is automatically controlled so that the in-vehicle temperature is maintained to the set temperature. The temperature set by the PTC (Potentio Temperature Control) and the temperature detected by the invehicle sensor and ambient sensor are compensated by the sunload sensor signal. The auto amplifier then determines fan speed from the ON-OFF operation of the A/C switch. The fan speed decision by the auto amplifier activates the fan relay and the blower fan motor rotates. When the A/C switch is ON, fan speed is activated in 4 steps, HI, MH, ML, and LO. When the A/C switch is OFF, fan speed is activated in 3 steps, MH, ML, and LO.

Auto amplifier

HI relay

Constant voltage transformation Air mix door position arithmetic circuit In-vehicle sensor Ambient sensor Sunload sensor

A/C operation signal detection

Blower motor

Resistor MH relay

Sunload compensation Air flow volume arithmetic circuit

ML relay

A/C switch

LO relay

Fan switch (AUTO) KHA130

HA-95

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)

SHA573CC

HI relay

Blower motor

Signals from each sensor, PTC, A/C switch etc. are sent to the air flow volume arithmetic circuit in the auto amplifier. Air flow volume is determined by this circuit. (1) When the air flow volume is set to ML The air flow volume arithmetic circuit gives current to Tr p 3 , which turns the ML relay on. Thus, the blower motor rotates in the ML condition.

Resistor MH relay Air flows volume arithmetic circuit

ML relay

Fan switch (AUTO)

A/C (LO) relay

SHA574CA

HA-96

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) (2) When set to HI The air flow volume arithmetic circuit gives current to Tr p 1 , which turns the HI relay on. Thus, the blower motor rotates in the HI condition. Also, Tr p 2 and Tr p 3 are receiving current and as a result the ML and MH relays are on. Auto amp.

HI relay

Blower motor Resistor

MH relay Air flows volume arithmetic circuit

ML relay

Fan switch (AUTO)

LO relay

SHA574CA

Auto amp.

(3) When set to LO The air flow volume arithmetic circuit does not give any current to Tr p 1 , p 2 nor p 3 . Only the LO relay turns on and so the blower motor rotates in the LO condition.

HI relay

Blower motor

Resistor MH relay Air flows volume arithmetic circuit

ML relay

Fan switch (AUTO)

LO relay

SHA576CA

HA-97

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d)

STARTING FAN SPEED CONTROL

Blower speed

The starting fan control system is so designed to prevent excess cold air from being expelled after the engine is started when the engine coolant temperature is low. The component parts related to this system are the water temperature sensor microswitch, HI, MH, ML and LO relays, blower motor, resistance and auto amplifier. When the fan switch is set to AUTO, the mode is selected either B/L, FOOT or FOOT/DEF and the engine coolant temperature is below 56°C (133°F), the speed of the blower motor is fixed in the LO position.

1.0

0 (32)

50 (122)

°C (°F)

Auto amp. . .

Constant voltage transformation

Blower motor

HI relay

.

Sensor voltage

Air mix door position arithmetic circuit

Air flow volume arithmetic circuit

Mode switch

Resistor MH relay

ML relay

LO relay

Water temperature meter

Fan switch (AUTO)

Thermal transmitter

SHA188DA

LO, ML, MH AND HI RELAYS . . .

.

HI relay

ML relay

LO relay

The LO and ML relays are located on the auto amplifier bracket, and the MH and HI relays are installed on the back side of the audio unit. Each fan relay operates according to the air flow volume determined by the auto amplifier. The blower motor then operates accordingly.

MH relay

NHA304

HA-98

AUTO SYSTEM DESCRIPTION Control System Output Components (Cont’d) IGN

ACC

Auto amplifier HI relay

Resistor MH relay

Air flows volume arithmetic circuit

ML relay

LO relay

Fan switch (AUTO)

SHA578CA

HA-99

AUTO

SERVICE PROCEDURES HFC-134a (R-134a) Service Procedure

SETTING OF SERVICE TOOLS AND EQUIPMENT DISCHARGING REFRIGERANT WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

Shut-off valve

A/C service valve

Recovery/Recycling/Recharghing equipment SHA539DC

EVACUATING SYSTEM AND CHARGING REFRIGERANT

Manifold gauge set Shut-off valve

Shut-off valve

A/C service valve

A/C service valve

For charging

Refrigerant container (HFC-134a) Weight scale

Recovery/Recycling/Recharging equipment

For evacuating vacuum pump

SHA540DC

HA-100

SERVICE PROCEDURES HFC-134a (R-134a) Service Procedure (Cont’d) Set the recovery/recycling equipment.

Recovered lubricant. HA-100.

H

Discharge refrigerant into recovery/ recycling equipment. H

Repair or replace parts. H

Evacuate the unwanted air in charging hoses. H

Evacuating (over 25 minutes). H E

Check airtightness H

E

Repair.

E

Repair.

E

Repair.

*-1

Partial charging [approx. 200 g (7.05 oz)]. H

Preliminary refrigerant leak check. H

*-1

Complete charging [specified amount -200 g (7.05 oz)] H

*-2

Check for refrigerant leaks. H

Check for A/C operation and A/C cooling performance H

Remove service couplers from A/C service valves. H

Recover refrigerant in charging hoses. H

Remove service tools.

Note: *-1 Before charging refrigerant, ensure engine is OFF. *-2 Before checking for leaks, start engine to activate air conditioner system then turn it OFF. Service valve caps must be attached to valves (to prevent leakage).

HA-101

AUTO

AUTO

SERVICE PROCEDURES Maintenance of Lubricant Quantity in Compressor

The lubricant used to lubricate the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: ● Lack of lubricant: May lead to a seized compressor ● Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT CR-14 Name: Nissan A/C System Oil Type R Part number: KLH00-PAGR0 CSV613 Name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0

CHECKING AND ADJUSTING Adjust the lubricant quantity according to the flowchart shown below.

START H

Yes

Can lubricant return operation be performed? ● A/C system works properly. ● There is no evidence of a large amount of lubricant leakage.

E

No

H

Should the compressor be replaced? No

F

Yes

H

A p

(Go to next page.)

H

Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.)

Yes

E

After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added Lubricant to be added to system Part replaced

No

H

Carry out the A/C performance test.

Perform lubricant return operation, proceeding as follows: -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------1. Start engine, and set the following conditions: ● Test condition Engine speed: Idling to 1,200 rpm A/C or AUTO switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] 2. Next item is for CSV613 compressor. Connect the manifold gauge, and check that the high pressure side pressure is 588 kPa (5.9 bar, 6 kg/cm2, 85 psi) or higher. If less than the reference level, attach a cover to the front face of the condenser to raise the pressure. 3. Perform lubricant return operation for about 10 minutes. 4. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation.

F

Amount of lubricant m (Imp fl oz)

Remarks

Evaporator

75 (2.6)

—

Condenser

75 (2.6)

—

Liquid tank

5 (0.2)

Add if compressor is not replaced. *1

In case of refrigerant leak

30 (1.1)

Large leak

—

Small leak*2

*1: If compressor is replaced, addition of lubricant is included in the flow chart. *2: If refrigerant leak is small, no addition of lubricant is needed.

HA-102

SERVICE PROCEDURES Maintenance of Lubricant Quantity in Compressor (Cont’d)

AUTO

A p

H

1.Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. 2. Remove the drain plug of the “old”(removed) compressor (applicable only to V-5, V-6, DKS-16H or DKS-17CH compressor). Drain the lubricant into a graduated container and recordthe amount of drained lubricant. 3. Remove the drain plugand drain the lubricant from the “new” compressor into aseparate, clean container. 4. Measure an amount of newlubricant installed equal to amount drained from “old” compressor. Add this lubricant to “new” compressor through thesuction port opening. 5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compressor through the suction port opening. 6.Torque the drain plug. CWV618 or CSV613compressor: 18 - 19 (1.8 - 1.9 kg-m, 13 - 14 ft-lb) DKS-16Hcompressor: 14 - 16 (1.4 - 1.6 kg-m, 10 - 12 ft-lb) DKS-17CHcompressor: 14 - 16 (1.4 - 1.6 kg-m, 10 - 12ft-lb) 7. If the liquid tank also needs tobe replaced, add an additional 5 m (0.2 Imp fl oz) of lubricant atthis time. Do not add this 5 m (0.2 Imp fl oz) of lubricantif only replacing thecompressor.

Recovery/ Recycling equipment

New compressor

Old compressor

Record amount Drain lubricant from new compressor into clean container

Record amount

Reinstall “X” m + “Y” m of newlubricant

New lubricant

New compressor Add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) ofnew lubricant when replacing liquid tank.

RHA065DD

HA-103

AUTO

SERVICE PROCEDURES Refrigerant Lines ●

Refer to page HA-4 regarding “Precautions for RefrigerantConnection”.

LHD MODELS SEC. 271 ⋅ 274 ⋅ 276 Hexagonal socket screw Expansion valve

2.9 - 4.4N·m (0.3 - 0.45 kg-m, 26.0 - 39.1 in-lb)

KHA051

SEC. 271 ⋅ 274 ⋅ 276

G p

E p

B p

17 19 A p

F p

p

Pressure switch H p

D p

l ll l

: Refrigerant leak checking order : (Tightening torque) : (Wrench size) : (O-ring size) : N·m (kg-m, ft-lb)

p C

: 25 - 34 (2.5 - 3.5, 18 - 25) : N·m (kg-m, in-lb) : 10 - 20 (1.0 - 2.0, 87 - 174) : 3 - 4 (0.3 - 0.4, 26 - 35) : 8 - 11 (0.8 - 1.1, 69 - 95) KHA052

HA-104

AUTO

SERVICE PROCEDURES Refrigerant Lines (Cont’d) RHD MODELS Hexagonal socket screw

SEC. 271 ⋅ 274 ⋅ 276

2.9 - 5.3N·m (0.3 - 0.54 kg-m, 26.0 - 46.9 in-lb) Expansion valve

KHA053

SEC. 271 ⋅ 274 ⋅ 276 Cooling unit

F p

p B

E p

Compressor Pressure D switch p

G p

p

p C

p A

l ll l

: Refrigerant leak checking order : (Tightening torque) : (Wrench size) : (O-ring size) : N·m (kg-m, ft-lb) : 25 - 34 (2.5 - 3.5, 18 - 25) : N·m (kg-m, in-lb)

Condenser

: 10 - 20 (1.0 - 2.0, 87 - 174) : 3 - 4 (0.3 - 0.4, 26 - 35) : 8 - 11 (0.8 - 1.1, 69 - 95) KHA054

HA-105

SERVICE PROCEDURES

AUTO

Checking Refrigerant Leaks PRELIMINARY CHECK Perform a visual inspection of all refrigeration parts, fittings, hoses, and components for signs of A/C lubricant leakage, damage and corrosion.

PRECAUTIONS FOR HANDLING LEAK DETECTOR

A/C leak detector

SHA705EB

When performing a refrigerant leak check, use an A/C leak detector or equivalent. Ensure that the instrument is calibrated and set properly per the operating instructions. The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance. Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and cleaners, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Do not allow the sensor tip of the detector to come into contact with any substance. This can also cause false readings and may damage the detector.

1. Position probe approximately 5 mm (3/16 in) away from point to be checked.

SHA707E

2. When testing, circle each fitting completely with probe.

SHA706E

HA-106

SERVICE PROCEDURES Checking Refrigerant Leaks (Cont’d)

AUTO

3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec.

SHA708E

CHECKING PROCEDURE To prevent inaccurate or false readings, make sure there is no refrigerant vapor or tobacco smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Charge the system with the specified amount of refrigerant. 2. Run the engine with the A/C compressor On for at least 2 minutes. 3. Stop engine.

Pressure

Pressure in high pressure line

Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector on the high pressure line. The pressure in the high pressure line will gradually drop after refrigerant circulation stops and pressure in the low pressure line will gradually rise, as shown in the graph. Leaks are more easily detected when pressure is high.

Pressure in low pressure line Time Compressor stops

RHA604B

4. Conduct the leak test from the high side to the low side at points p A through p H . Refer to HA-104, LHD models); p A through p G (Refer to HA-105, RHD models). Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detector probe completely around the connection/component. ● Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. ● Liquid tank Check the pressure switch, tube fitting and the fusible plug mounts. ● Service valves Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). ● Cooling unit (Evaporator) Turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Insert the leak detector probe into the drain hose immediately after stopping the engine. (Keep the probe inserted for at least ten seconds.) 5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check.

HA-107

SERVICE PROCEDURES Checking Refrigerant Leaks (Cont’d)

AUTO

6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. 7. Start engine.

HA-108

AUTO

SERVICE PROCEDURES Compressor Mounting CD engine models SEC. 274⋅275

37 - 50 (3.8 - 5.1, 27 - 37)

45 - 60 (4.6 - 6.1, 33 - 44)

Bracket

27 - 35 (2.8 - 3.6, 20 - 26)

Idler pulley

Compressor

37 - 50 (3.8 - 5.1, 27 - 37) .

: N·m (kg-m, ft-lb) KHA056

HA-109

AUTO

SERVICE PROCEDURES Compressor Mounting (Cont’d) SR engine models SEC. 274⋅275

16 - 19 (1.6 - 1.9, 12 - 14)

45 - 60 (4.6 - 6.1, 33 - 44)

45 - 60 (4.6 - 6.1, 33 - 44)

16 - 19 (1.6 - 1.9, 12 - 14)

16 - 19 (1.6 - 1.9, 12 - 14) : N·m (kg-m, ft-lb)

45 - 60 (4.6 - 6.1, 33 - 44) KHA057

QG engine models SEC.274⋅275

45 - 60 (4.6 - 6.1, 33 - 44)

31 - 40 (3.1 - 4.1, 23 - 29) 25 - 31 (2.4 - 3.2, 18 - 23)

34 - 46 (3.4 - 4.6, 25 - 33)

31 - 40 (3.1 - 4.1, 23 - 29) : N·m (kg-m, ft-lb) NHA316

HA-110

SERVICE PROCEDURES Compressor Mounting (Cont’d)

AUTO

Belt tension ●

Refer to MA section.

Fast Idle Control Device (FICD) ●

refer to EC section.

Compressor — Model CR-14 (Calsonic make) SEC. 274

Magnet clutch assembly

Field coil

Compressor

Snap ring

Pulley assembly Shim Snap ring Clutch disc Center bolt

12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11ft-lb) RHA314E

Compressor Clutch REMOVAL ● ●

When removing center bolt, hold clutch disc with clutch disc wrench. Take off clutch disc.

RHA315EA

●

Remove snap ring (which secures rotor pulley) by using external snap ring pliers.

Snap ring pliers

RHA316E

HA-111

SERVICE PROCEDURES Compressor Clutch (Cont’d) Gear puller

●

Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.

●

Remove snap ring (which secures field coil) by using external snap ring pliers.

Rotor pulley

Pulley puller claws

Pulley assembly

AUTO

RHA317E

External snap ring pliers

.

Clutch disc Snap ring

RHA318E

Field coil Snap ring

INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, the clutch disc and pulley should be replaced.

Pulley Pulley assembly Center bolt

Shim

RHA319E

Check the appearance of the pulley assembly. If the contact surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and clutch disc should be replaced. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

Coil Check coil for loose connection or cracked insulation.

INSTALLATION ● Position the field coil. Be sure to align the coil’s pin with the hole in compressor’s front head. ● Install snap ring (which secures field coil) by using external snap ring pliers.

RHA320E

HA-112

SERVICE PROCEDURES Compressor Clutch (Cont’d) ● ●

Snap ring

Position and install pulley assembly securely by using plastic hammer. Install snap ring (which secures rotor pulley) by using external snap ring pliers.

RHA321EA

●

Shim

AUTO

Install the clutch disc on the drive shaft, together with the original shim(s). Press the disc down by hand.

Clutch disc

RHA322E

Using the clutch wrench disc to prevent clutch disc rotation, tighten the bolt to 12 to 15 N·m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. ●

Torque wrench

RHA323E

●

Clutch disc Pulley assembly

Check clearance around the entire periphery of clutch disc. Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in) If the specified clearance is not obtained, replace adjusting spacer and readjust.

BREAK-IN OPERATION 0.3 - 0.6 mm (0.012 - 0.024 in)

Feeler gauge

RHA087E

When replacing compressor clutch assembly, do not forget break-in operation, accomplished by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.

Thermal Protector INSPECTION ● Thermal protector

●

When servicing, do not allow foreign matter to get into compressor. Check continuity between two terminals.

SHA055B

HA-113

SERVICE PROCEDURES

AUTO

CSV613 Compressor

Center bolt 14 N·m (1.4 kg-m, 10 ft-lb) Clutch disc Snap ring

Compressor unit

Field coil Snap ring Pulley assembly Shim KHA114

KV99106100

Compressor Clutch REMOVAL ●

When removing center bolt, hold clutch disc with clutch disc wrench.

RHA136E KV99232340

RHA399FA

HA-114

SERVICE PROCEDURES Compressor Clutch (Cont’d)

AUTO

●

Remove the clutch disc using the clutch disc puller. Insert the holder’s three pins into the holes in the clutch disc. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the clutch disc. After removing the clutch disc, remove the shims from either the drive shaft or the clutch disc.

●

Remove the snap ring using external snap ring pliers.

●

Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.

●

Remove the field coil harness clip. Remove the snap ring using external snap ring pliers.

KV99106100

RHA124FA

External snap ring pliers

Snap ring RHA138E

Pulley puller

Pulley assembly RHA139E

●

Snap ring

RHA145E

INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Pulley Coil Pulley Clutch disc RHA126F

Check the appearance of the pulley assembly. Check if the contact surface of the pulley shows sign of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

HA-115

SERVICE PROCEDURES Compressor Clutch (Cont’d) Field coil

AUTO

Coil Check coil for loose connection or cracked insulation.

INSTALLATION ● Install the field coil. Be sure to align the coil’s pin with the hole in the compressor’s front head. ● Install the field coil harness clip using a screwdriver.

Pin

RHA142E

●

Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.

●

Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand.

KV99106200

Snap ring Pulley assembly

RHA143E

Shim

RHA127F

Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N·m (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. ●

Torque wrench

RHA086E

●

Clutch disc Pulley assembly

Check clearance around the entire periphery of clutch disc. Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in) If the specified clearance is not obtained, replace adjusting spacer and readjust.

0.3 - 0.6 mm (0.012 - 0.024 in)

Feeler gauge

NHA310

HA-116

SERVICE PROCEDURES

AUTO

BREAK-IN OPERATION When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.

Ventilation Air Filter Ventilation air filter

Fresh air Recirculation air

Evaporator

FUNCTION Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing ventilation air filter into cooling unit.

Intake unit RHA336F

REPLACEMENT TIMING Replace ventilation air filter every 2 years or 30,000 km (15,000 miles). Caution label is fixed inside the glove box.

SHA868E

REPLACEMENT PROCEDURES ●

Ventilation air filter

● ●

Remove instrument lower cover with glove box. Refer to BT section. Take out ventilation air filter which is secured with one clip, from cooling unit. Replace with new one and reinstall instrument lower cover and glove box.

KHA058

HA-117

AUTO

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications COMPRESSOR CD20T engine

SR20DE, QG16⋅18DE engine

CALSONIC make CR-14

CALSONIC make CSV613

Vane rotary

Variable displacement

144 (8.79)

6 to 125 (0.37 to 7.63)

Model Type 3

Displacement

cm (cu in)/Rev

Clockwise (Viewed from drive end)

Direction of rotation Drive belt

CD engine model: Type A

Poly V

LUBRICANT Model

CALSONIC make CR-14

CALSONIC make CSV613

Name

Nissan A/C System Oil Type R

Nissan A/C system Oil Type S

KLH00-PAGR0

KLH00-PAGS0

Total in system

180 (6.3)

200 (7.04)

Compressor (Service parts) charging amount

180 (6.3)

200 (7.04)

Part number Capacity

m (Imp fl oz)

REFRIGERANT Type Capacity

HFC-134a kg (lb)

0.60 ± 0.05 (1.32 ± 0.11)

Inspection and Adjustment ENGINE IDLING SPEED When A/C is ON Refer to EC section.

BELT TENSION

COMPRESSOR Model

CR-14/CSV613

Clutch disc-to-pulley clearance mm (in)

0.3 - 0.6 (0.012 - 0.024)

Refer to Checking Drive Belts (MA section).

HA-118

ELECTRICAL SYSTEM SECTION

EL

When you read wiring diagrams: ● Read GI section, “HOW TO READ WIRING DIAGRAMS”. When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.

CONTENTS PRECAUTIONS AND PREPARATION.......................... 5 Precautions ................................................................ 5 HARNESS CONNECTOR.............................................. 6 Description ................................................................. 6 STANDARDIZED RELAY .............................................. 8 Description ................................................................. 8 POWER SUPPLY ROUTING ....................................... 10 Schematic ................................................................ 10 Wiring Diagram - POWER - .................................... 12 Fuse ......................................................................... 22 Fusible Link.............................................................. 22 Circuit Breaker Inspection ....................................... 22 GROUND DISTRIBUTION........................................... 23 BATTERY ..................................................................... 29 How to Handle Battery ............................................ 29 Battery Test and Charging Chart............................. 32 Service Data and Specifications (SDS)................... 36 STARTING SYSTEM ................................................... 37 Wiring Diagram - START -....................................... 37 Trouble Diagnoses................................................... 40 Construction............................................................. 41 Removal and Installation ......................................... 47 Inspection................................................................. 47 Assembly ................................................................. 51 Service Data and Specifications (SDS)................... 52 CHARGING SYSTEM .................................................. 53 Wiring Diagram - CHARGE -................................... 53 Trouble Diagnoses................................................... 55 Construction............................................................. 56 Removal and Installation ......................................... 60

Disassembly............................................................. 60 Inspection................................................................. 60 Assembly ................................................................. 62 Service Data and Specifications (SDS)................... 63 COMBINATION SWITCH............................................. 64 Combination Switch/Check...................................... 64 STEERING SWITCH.................................................... 65 Check....................................................................... 65 Replacement............................................................ 66 HEADLAMP (WITHOUT DAYTIME LIGHT SYSTEM) - CONVENTIONAL TYPE - ........................ 67 Wiring Diagram - H/LAMP -..................................... 67 Trouble Diagnoses................................................... 69 Bulb Replacement ................................................... 70 Aiming Adjustment ................................................... 70 HEADLAMP (WITHOUT DAYTIME LIGHT SYSTEM) - XENON TYPE - ........................................ 72 System Description.................................................. 72 Wiring Diagram - H/LAMP -..................................... 73 Trouble Diagnoses................................................... 75 Bulb Replacement ................................................... 76 HEADLAMP - DAYTIME LIGHT SYSTEM - ............... 78 Schematic ................................................................ 78 Wiring Diagram - DTRL -......................................... 79 HEADLAMP - DAYTIME LIGHT SYSTEM WITH XENON TYPE - ............................................................ 82 Schematic ................................................................ 82 Wiring Diagram - DTRL -......................................... 83 HEADLAMP - DAYTIME LIGHT SYSTEM - ............... 86 Trouble Diagnoses................................................... 86

EL

HEADLAMP - HEADLAMP AIMING CONTROL (MANUAL) - ................................................................. 87 Wiring Diagram - H/AIM - ........................................ 87 HEADLAMP - HEADLAMP AIMING CONTROL (AUTO) -....................................................................... 91 System Description.................................................. 91 Initialisation .............................................................. 91 Component Parts and Harness ............................... 92 Wiring Diagram - H/AIM - ........................................ 93 Trouble Diagnosis .................................................... 95 Removal and Installation ......................................... 99 PARKING, LICENSE AND TAIL LAMPS.................. 100 Wiring Diagram - TAIL/L -...................................... 100 STOP LAMP .............................................................. 104 Wiring Diagram - STOP - ...................................... 104 BACK-UP LAMP........................................................ 107 Wiring Diagram - BACK/L - ................................... 107 FRONT FOG LAMP....................................................110 Wiring Diagram - F/FOG - ......................................110 Aiming Adjustment .................................................. 111 Bulb Specifications ................................................. 111 REAR FOG LAMP ......................................................112 Wiring Diagram - R/FOG -......................................112 TURN SIGNAL AND HAZARD WARNING LAMPS ..117 Schematic ...............................................................117 Wiring Diagram - TURN - .......................................118 Trouble Diagnoses................................................. 123 ILLUMINATION .......................................................... 124 Schematic .............................................................. 124 Wiring Diagram - ILL - ........................................... 125 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS ....................................... 130 System Description................................................ 130 Schematic .............................................................. 131 Wiring Diagram - INT/L - ....................................... 132 BULB SPECIFICATIONS .......................................... 137 Headlamp............................................................... 137 Exterior Lamp ........................................................ 137 Interior Lamp.......................................................... 137 METER AND GAUGES ............................................. 138 System Description................................................ 138 Combination Meter ................................................ 139 Wiring Diagram - METER -/MODELS BEFORE VIN - P11U0548750............................................... 141 Schematic .............................................................. 144 Wiring Diagram - METER -/M/T MODELS AFTER VIN - P11U0548750.................................. 146 Wiring Diagram - METER -/CVT MODELS AFTER VIN - P11U0548750.................................. 149 Combination Meter Self-Diagnosis ........................ 152 Trouble Diagnoses (Models before VIN P11U0548750) ....................................................... 155 Trouble Diagnoses (Models after VIN P11U0548750) ....................................................... 159 Fuel Level Sensor Unit Check............................... 164 QG & SR Engine Models ...................................... 164

CD20T Engine Models .......................................... 164 Thermal Transmitter Check ................................... 164 WARNING LAMPS .................................................... 165 Warning Lamps/Schematic .................................... 165 Wiring Diagram - WARN - ..................................... 167 Electrical Components Inspection ......................... 179 WARNING CHIME ..................................................... 180 System Description................................................ 180 Wiring Diagram - CHIME - .................................... 181 Trouble Diagnoses................................................. 183 Electrical Components Inspection ......................... 185 FRONT WIPER AND WASHER ................................ 186 System Description................................................ 186 Wiring Diagram - WIPER - .................................... 188 Removal and Installation ....................................... 190 Front Washer Nozzle Adjustment .......................... 192 Front Washer Tube Layout .................................... 192 REAR WIPER AND WASHER .................................. 193 System Description................................................ 193 Wiring Diagram - WIP/R -...................................... 195 Removal and Installation ....................................... 197 Washer Nozzle Adjustment ................................... 197 Washer Tube Layout ............................................. 199 Check Valve........................................................... 199 HEADLAMP WASHER .............................................. 200 Wiring Diagram - HLC -......................................... 200 Washer Tube Layout ............................................. 202 Check Valve........................................................... 202 HORN, CIGARETTE LIGHTER AND CLOCK .......... 203 Wiring Diagram - HORN - ..................................... 203 REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER ............................................... 207 System Description................................................ 207 Schematic .............................................................. 208 Wiring Diagram - DEF -......................................... 209 Trouble Diagnoses................................................. 212 Electrical Components Inspection ......................... 213 Filament Check...................................................... 213 Filament Repair ..................................................... 214 AUDIO ........................................................................ 216 Anti-theft System ................................................... 216 Speed Dependent Volume Control........................ 217 Personal Audio Settings ........................................ 217 Schematic .............................................................. 218 Wiring Diagram - AUDIO -..................................... 219 Trouble Diagnoses................................................. 226 Inspection............................................................... 228 AUDIO ANTENNA ..................................................... 229 Location of Antenna............................................... 229 ELECTRIC SUNROOF .............................................. 230 Wiring Diagram - SROOF - ................................... 230 POWER DOOR MIRROR .......................................... 231 Wiring Diagram - MIRROR - ................................. 231 POWER SEAT ........................................................... 233 Power Seat/Wiring Diagram - SEAT - ................... 233 HEATED SEAT .......................................................... 234

EL-2

Heated Seat/Wiring Diagram - HSEAT - ............... 234 POWER WINDOW ..................................................... 236 System Description................................................ 236 Schematic .............................................................. 239 Wiring Diagram - WINDOW - ................................ 240 Trouble Diagnoses................................................. 243 POWER DOOR LOCK............................................... 245 System Description/Door Lock for LHD Models.... 245 Schematic .............................................................. 246 Wiring Diagram - D/LOCK -................................... 248 Trouble Diagnoses................................................. 256 POWER DOOR LOCK - SUPER LOCK -................. 265 Component Parts Location .................................... 265 System Description/Super Lock for RHD Models . 266 Schematic .............................................................. 268 Wiring Diagram - S/LOCK -................................... 270 Trouble Diagnoses................................................. 283 MULTI-REMOTE CONTROL SYSTEM ..................... 296 System Description................................................ 296 Schematic .............................................................. 297 Wiring Diagram - MULTI - ..................................... 298 Trouble Diagnoses................................................. 303 ID Code Entry Procedure ...................................... 305 TIME CONTROL UNIT (TCU) ................................... 306 System Description................................................ 306 Trouble Diagnosis .................................................. 309 THEFT WARNING SYSTEM ......................................311 Components Parts and Harness Connector Location ..................................................................311

System Description................................................ 312 Schematic .............................................................. 315 Wiring Diagram - THEFT -..................................... 316 Trouble Diagnoses................................................. 328 NATS (NISSAN ANTI-THEFT SYSTEM)................... 342 Component Parts Location .................................... 342 Wiring Diagram - NATS -....................................... 343 NATS (NISSAN ANTI-THEFT SYSTEM)................... 345 System Description................................................ 345 System Composition.............................................. 346 CONSULT-II ........................................................... 347 Trouble Diagnoses................................................. 349 How to Replace NATS IMMU................................ 363 LOCATION OF ELECTRICAL UNITS....................... 365 Engine Compartment............................................. 365 Passenger Compartment....................................... 366 HARNESS LAYOUT .................................................. 368 Outline.................................................................... 368 How to Read Harness Layout ............................... 369 Engine Control Harness ........................................ 370 Engine Room Harness .......................................... 376 Main Harness......................................................... 382 Body Harness ........................................................ 386 Air Conditioner Harness ........................................ 402 Room Lamp Harness............................................. 403 Back Door Harness ............................................... 404 Front Door Harness (LH side) ............................... 406 Front Door Harness (RH side) .............................. 407 Rear Door Harness................................................ 408

WIRING DIAGRAM REFERENCE CHART ECCS (Ignition system) .......................................................................................................................... AUTOMATIC TRANSAXLE CONTROL SYSTEM ................................................................................... ANTI-LOCK BRAKE SYSTEM ................................................................................................................ SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” ........................................................................ HEATER AND AIR CONDITIONER .........................................................................................................

EL-3

EC SECTION AT SECTION BR SECTION RS SECTION HA SECTION

NOTE

EL-4

PRECAUTIONS AND PREPARATION Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel and on the instrument panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along with the seat belt help to reduce the risk or severity of injury to the driver and front passenger in a side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision), wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative (which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation), all maintenance must be performed by an authorized NISSAN dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT-TENSIONER” connector) can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). Not use electrical test equipment on any circuit related to the SRS.

EL-5

HARNESS CONNECTOR Description HARNESS CONNECTOR (TAB-LOCKING TYPE) The tab-locking type connectors help prevent accidental looseness or disconnection. The tab-locking type connectors are disconnected by pushing or lifting the locking tab(s). Refer to the illustration below. Refer to the next page for description of the slide-locking type connector. CAUTION: Do not pull the harness or wires when disconnecting the connector. [Example] ● ●

PUSH

Terminal retainer PUSH

Packing (Water-proof type) Connector housing

LIFT

PUSH PUSH

PUSH PUSH

PUSH (For combination meter)

(For relay)

SEL769D

EL-6

HARNESS CONNECTOR Description (Cont’d) HARNESS CONNECTOR (SLIDE-LOCKING TYPE) A new style slide-locking type connector is used on certain systems and components, especially those related to OBD. ● The slide-locking type connectors help prevent incomplete locking and accidental looseness or disconnection. ● The slide-locking type connectors are disconnected by pushing or lifting the slider. Refer to the illustration below. CAUTION: Do not pull the harness or wires when disconnecting the connector. Be careful not to damage the connector support bracket when disconnecting the connector. [Example] ●

Waterproof type

쑗1

Firmly grasp shell of connector housing at A.

쑗2

Push slider until connector pops or snaps apart.

쑗3

Disconnect harness connector.

Non-waterproof type

쑗1

Firmly grasp shell of connector housing at A.

쑗2

Pull back on the slider while pulling apart male and female halves of connector.

쑗3

Disconnect harness connector.

SEL769V

EL-7

STANDARDIZED RELAY Description NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

NORMAL OPEN RELAY

NORMAL CLOSED RELAY

MIXED TYPE RELAY

SW 1 “OFF”

Flows

Flows

Does not flow

Does not flow

SW 1

SW 1

BATTERY

SW 1

BATTERY

BATTERY

Flows Does not flow

SW 1 “ON”

Does not flow

Flows

SW 1

SW 1

BATTERY

SW 1

BATTERY

BATTERY SEL881H

TYPE OF STANDARDIZED RELAYS 1M

.......... 1 Make

2M

1T

.......... 1 Transfer

1M⋅1B .......... 1 Make 1 Break

1M

.......... 2 Make

2M 1M

2M

1T

1M⋅1B

1T 1B

1M

SEL882H

EL-8

STANDARDIZED RELAY Description (Cont’d) Type

Outer view

Circuit

Connector symbol and connection

Case color

BLACK

BROWN

GRAY

BLUE

The arrangement of terminal numbers on the actual relays may differ from those shown above.

EL-9

SEL188W

POWER SUPPLY ROUTING Schematic BATTERY

COMBINATION SWITCH LIGHTING SWITCH

R/FOG SWITCH

IGNITION SWITCH

ACCESSORY RELAY

POWER FUSE IGNITION RELAY

POWER WINDOW RELAY

REAR WINDOW DEFFOGGER RELAY

TIME CONTROL UNIT

YEL218C

EL-10

POWER SUPPLY ROUTING Schematic (Cont’d)

YEL948C

EL-11

POWER SUPPLY ROUTING Wiring Diagram — POWER — BATTERY POWER SUPPLY — IGNITION SWITCH IN ANY POSITION Gasoline engine models

YEL949C

EL-12

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) Diesel engine models

YEL950C

EL-13

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

To ELPOWER-01

To ELPOWER-05 FUSE AND FUSIBLE LINK BOX

To ELPOWER-02

To EL-H/LAMP EL-DTRL EL-HLC EL-H/AIM

To EL-HORN To EL-H/LAMP EL-DTRL EL-HLC

To EL-DTRL

To EL-H/LAMP EL-DTRL EL-H/AIM

To EC-MAIN EC-EGR EC-EGVC/V EC-AAC/V EC-TP/SW EC-IGN/SG AT-MAIN

To EC-MAIN EC-CMPS EC-MAFS EC-EGR EC-EGVC/V EC-AAC/V EC-TP/SW EC-IGN/SG EC-POS EC-PHASE AT-MAIN

LIGHTING SWITCH OFF

1ST

2ND

OFF

1ST

2ND

ON OFF REAR FOG LAMP SWITCH

COMBINATION SWITCH

FRONT AND REAR OFF

OFF FRONT

FRONT AND REAR

FRONT

FRONT AND REAR FOG LAMP SWITCH

: With gasoline engine : With diesel engine

To ELPOWER-06

Next page

: With daytime light system : Without daytime light system

To EL-R/FOG

: With front fog lamp : Without front fog lamp

To EL-HLC EL-DTRL EL-H/AIM EL-ILL

YEL222C

EL-14

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

YEL951C

EL-15

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

YEL952C

EL-16

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) To EL-POWER-03 : With daytime light system : Without daytime light system : With glove box lamp

DAYTIME LIGHT CONTROL UNIT To EL-TAIL/L EL-H/AIM

FUSE BLOCK (J/B)

TIME CONTROL UNIT

To EL-ILL

To EL-ILL

To EL-ILL

To EL-TAIL/L EL-H/AIM EL-ILL

To EL-ILL EL-AUDIO

To EL-ILL

To EL-ILL

To EL-ILL

To EL-ILL

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) : This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL225C

EL-17

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) ACCESSORY POWER SUPPLY — IGNITION SWITCH IN “ACC” OR “ON” BATTERY : With gasoline engine

Refer to EL-POWER-01, EL-POWER-02, EL-POWER-03, EL-POWER-04 EL-POWER-05

: With diesel engine : With gasoline engine and with XENON headlamp : Except

OFF

ACC

ST

IGNITION SWITCH

POWER FUSE 15A

ON

ACCESSORY RELAY

FUSE BLOCK (J/B)

To EL-AUDIO EL-MIRROR

To EL-HORN

To EL-HORN

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

YEL226C

EL-18

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) IGNITION POWER SUPPLY — IGNITION SWITCH IN “ON” AND/OR “START” BATTERY Refer to EL-POWER-01, EL-POWER-02, EL-POWER-03, EL-POWER-05

To EL-POWER-10 ST

OFF

: With gasoline engine : With diesel engine

IGNITION SWITCH

ACC ON

Next page

To EC-MAIN EC-IGN/SG FUSE BLOCK (J/B)

Next page IGNITION RELAY To EL-POWER-10

Next page

To BR-ABS

To EL-WIP/R

To EC-VSS EC-MIL/DL EC-GLOW BR-ABS RS-SRS EL-HORN EL-WARN EL-METER EL-CHARGE EL-ILL EL-H/AIM AT-NONDTC To EL-WIP/R

To EL-NATS EL-HLC

To RS-SRS

To EC-VSS AT-PNP/SW AT-NONDTC EL-BACK/L EL-METER

To EC-INJECT EC-MIL/DL EC-FUEL EC-MAIN

To EL-DTRL HA-A/C EC-COOL/F

To EC-O2S1B1 EC-O2H1B1 EC-O2S2B1 EC-O2H2B1 EC-FUEL EC-PGC/V EC-SWL/V EC-IVC EC-EGRC/V EC-HO2S EC-AAC/V EC-MAIN EL-START EL-DTRL HA-A/C EC-COOL/F

REFER TO THE FOLLOWING

FUSE BLOCK Junction Box (J/B)

YEL227C

EL-19

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d)

Preceding page

FUSE BLOCK (J/B)

Preceding page Next page REAR WINDOW DEFOGGER RELAY

FUEL PUMP RELAY

TIME CONTROL UNIT

To EL-WIPER

To EL-WIP/R EL-WIPER

To EC-F/PUMP

To HA-HEATER HA-A/C

To EL-HSEAT

To EL-DEF

To EL-DEF

To EC-F/PUMP

REFER TO THE FOLLOWING FUSE BLOCK Junction Box (J/B)

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL228C

EL-20

POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) : CVT models To EL-POWER-08 OFF

IGNITION SWITCH

ST

: M/T models : With gasoline engine : With diesel engine

ON ACC

To EL-START

FUSE BLOCK (J/B)

To EL-POWER-08 Preceding page BLOWER RELAY

To EL-POWER-01 POWER WINDOW RELAY

To EL-POWER-02 To EL-POWER-08

To EL-SROOF

To EL-WINDOW

To HA-HEATER HA-A/C

To HA-A/C EC-FICD EC-A/CCUT

To HA-HEATER HA-A/C EC-FICD EC-A/CCUT

To EL-DTRL EC-S/SIG EC-MAIN

REFER TO THE FOLLOWING

FUSE BLOCK Junction Box (J/B)

YEL250B

EL-21

POWER SUPPLY ROUTING Fuse

OK

a. If fuse is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. c. Do not partially install fuse; always insert it into fuse holder properly. d. Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not used for a long period of time.

Blown CEL083

Fusible Link Fusible link

Fuse

NEL545

A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: ● If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem. ● Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness or vinyl or rubber parts.

Circuit Breaker Inspection

Time (sec.)

For example, when current is 30A, the circuit is broken within 8 to 20 seconds.

Break point

Current (A) SBF284E

Circuit Breaker (PTC Thermistor Type) The PTC thermister generates heat in response to current flow. The temperature (and resistance) of the thermister element varies with current flow. Excessive current flow will cause the element’s temperature to rise. When the temperature reaches a specified level, the electrical resistance will rise sharply to control the circuit current. Reduced current flow will cause the element to cool. Resistance falls accordingly and normal circuit current flow is allowed to resume. SEL109W

EL-22

GROUND DISTRIBUTION GROUND M6/M26/M28

E10

CONNECT TO A/C AUTO AMP. A/C CONTROL PANEL A/C HIGH RELAY A/C LOW RELAY (Type-1) A/C LOW RELAY (Type-2) A/C MH RELAY (Type-1) A/C MED-HIGH RELAY (Type-2) A/C MED-LOW RELAY AUDIO CIGARETTE LIGHTER SOCKET COMBINATION METER (ILLUMINATION) (Without illumination control switch) (Models before VIN P11U0548750) COMBINATION METER (ABS WARNING LAMP) (Models before VIN - P11U0548750) COMBINATION METER (AIR BAG WARNING LAMP) (Models before VIN - P11U0548750) COMBINATION METER (AIR BAG WARNING LAMP) (Models after VIN - P11U0548750) COMBINATION METER (HIGH BEAM INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (Hyper CVT M6 models) (Models before VIN - P11U0548750) COMBINATION METER (Hyper CVT M6 models) (Models after VIN - P11U0548750) COMBINATION METER (SPEEDOMETER) (Models before VIN P11U0548750) COMBINATION METER (SPEEDOMETER) (Models after VIN P11U0548750) COMBINATION METER (Models before VIN - P11U0548750) COMBINATION METER (Models after VIN - P11U0548750) COMBINATION METER (Models after VIN - P11U0548750) CONTROL DEVICE (Hyper CVT M6 models) CONTROL DEVICE (Hyper CVT models) DATA LINK CONNECTOR DATA LINK CONNECTOR (TERMINAL NO. 13) AIRBAG DIAGNOSIS SENSOR UNIT DONGLE CONTROL UNIT (RHD) DOOR MIRROR REMOTE CONTROL SWITCH FAN SWITCH FAN SWITCH (Gasoline engine) (without A/C) FUSE BLOCK (J/B) (IGNITION RELAY, BLOWER RELAY) FUSE BLOCK (J/B) (FRONT FOG LAMP RELAY)

CONN. M115 M44, M47 M119 M120 M123 M118 M122 M121 M42 M39 E124

EL-ILL

M38

BR-ABS

M38

RS-SRS

M89

RS-SRS

E124

EL-H/LAMP, EL-DTRL

M38

AT-NONDTC

M89

AT-NONDTC

M38

EC-VSS

M89

EC-VSS

M38 M89 E131 M79 M49 M59 M59 M87 M85 M5 M46 M46 M1 M1

EL-METER, EL-WARN, EL-HORN EL-METER, EL-WARN, EL-HORN AT-NONDTC, EL-ILL AT-NONDTC, EL-ILL AT-NONDTC, EL-ILL EC-MIL/DL RS-SRS RS-SRS EL-NATS, EL-AUDIO EL-MIRROR HA-HEATER EC-LOAD EL-POWER EL-F/FOG, EL-POWER EL-WINDOW, EL-SROOF, EL-POWER EL-ILL EL-TURN, EL-ILL EL-ILL AT-NONDTC EC-BRK/SW EL-ILL, EL-DEF HA-HEATER, EL-ILL EL-SLOOF EL-ILL EL-BUZZER, EL-S/LOCK, EL-D/LOCK, EL-THEFT, EL-DEF, EL-MULTI, EL-INT/L, EL-TURN EL-INT/L EL-INT/L EL-METER, EC-VSS BR-ABS

FUSE BLOCK (J/B) (POWER WINDOW RELAY)

M1

GLOVE BOX LAMP (ILLUMINATION) HAZARD SWITCH HEATER (ILLUMINATION) INDICATOR CONTROL UNIT (Hyper CVT M6 models) RDNT BRAKE SWITCH (RHD) (CD20 engine) A/C CONTROL PANEL (REAR WINDOW DEFOGGER SWITCH) A/C CONTROL PANEL (RECIRCULATION SWITCH) SUNROOF SWITCH SPOT LAMP

M24 M58 M45 M72 M64 M44 M47 R4 R5

TIME CONTROL UNIT

B96

VANITY MIRROR LAMP (LHD) VANITY MIRROR LAMP (RHD) VEHICLE SPEED SENSOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

R9 R2 F25 E78

EL-23

CELL CODE HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C HA-A/C EL-ILL, EL-AUDIO EL-HORN

GROUND DISTRIBUTION GROUND E11/E37

E68 E88 F9

CONNECT TO ACCESSORY RELAY BRAKE FLUID LEVEL SWITCH CLEARANCE LAMP LH CLEARANCE LAMP RH COMBINATION METER (FRONT FOG LAMP INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (FRONT FOG LAMP INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (REAR FOG LAMP INDICATOR) (Models before VIN - P11U0548750) COMBINATION METER (REAR FOG LAMP INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (HIGH BEAM INDICATOR) (Models after VIN - P11U0548750) COMBINATION METER (ILLUMINATION) (Models after VIN P11U0548750) COMBINATION METER (TURN) (Models before VIN P11U0548750) COMBINATION METER (TURN) (Models after VIN P11U0548750) COMBINATION SWITCH (FRONT WIPER SWITCH) COMBINATION SWITCH (TRIP COMPUTER SWITCH) COMBINATION SWITCH (TURN SIGNAL SWITCH) COOLING FAN MOTOR-1 (Gasoline engine) COOLING FAN MOTOR-2 (CD20 engine) COOLING FAN MOTOR-2 (QG18, SR20 engine) COOLING FAN MOTOR-2 (With A/C) (GA16 engine) COOLING FAN RELAY-2 (CD engine) DAYTIME LIGHT CONTROL UNIT FRONT FOG LAMP LH (Type-1) FRONT FOG LAMP LH (Type-2) FRONT FOG LAMP RH (Type-1) FRONT FOG LAMP RH (Type-2) FRONT TURN SIGNAL LAMP LH FRONT TURN SIGNAL LAMP RH FRONT WIPER MOTOR FRONT WIPER RELAY HEAD LAMP RELAY LH HEAD LAMP RELAY RH HEAD LAMP WASHER MOTOR HEAD LAMP WASHER SWITCH HEADLAMP AIMING MOTOR LH HEADLAMP AIMING MOTOR RH HEADLAMP LH HEADLAMP RH HOOD SWITCH NATS IMMU POWER STEERING OIL PRESSURE SWITCH (Gasoline) RDNT BRAKE SWITCH (LHD) (CD20 engine) REAR WIPER RELAY SEDIMENTER SENSOR SIDE TURN SIGNAL LAMP LH (Type-1) SIDE TURN SIGNAL LAMP LH (Type-2) SIDE TURN SIGNAL LAMP RH (Type-1) SIDE TURN SIGNAL LAMP RH (Type-2) TRIPLE-PRESSURE SWITCH (CD engine) WASHER LEVEL SWITCH ALTERNATOR (GA engine) ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) ALTERNATOR (QG16, QG18, SR20, CD engine)

EL-24

CONN. E95 E14 E85 E87

CELL CODE EL-POWER, EL-HORN EL-WARN EL-TAIL/L EL-TAIL/L

E124

EL-F/FOG

E131

EL-F/FOG

E124

EL-R/FOG

E131

EL-R/FOG

E131

EL-H/LAMP, EL-DTRL

E131

EL-ILL

E124

EL-TURN

E131

EL-TURN

E114 E114 E111 E19 E18 E28 E94 E54 E117 E6 E146 E34 E147 E8 E36 E62 E70 E74 E75 E38 E128 E4 E33 E5 E32 E12 E121 E60 E122 E52 E13 E9 E148 E59 E149 E20 E39 E71 E78 F10

EL-WIPER, EL-WIP/R EL-METER EL-TURN HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EC-COOL/F HA-A/C, EL-COOL/F EL-DTRL EL-F/FOG EL-F/FOG EL-F/FOG EL-F/FOG EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-WIPER EL-WIPER EL-H/LAMP, EL-DTRL EL-HLC, EL-H/LAMP, EL-DTRL EL-HLC EL-HLC, EL-ILL EL-H/AIM EL-H/AIM EL-H/LAMP, EL-DTRL EL-H/LAMP, EL-DTRL EL-THEFT EL-NATS EC-PST/SW EC-BRK/SW EL-WIP/R EL-WARN EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-TURN, EL-THEFT EL-TURN, EL-THEFT HA-A/C, EC-COOL/F EL-WARN EL-CHARGE BR-ABS EL-CHARGE

GROUND DISTRIBUTION GROUND F15/F18

CONNECT TO CAMSHAFT POSITION SENSOR (QG16, QG18 engine) CONDENSER (QG16, QG18 engine) CRANKSHAFT POSITION SENSOR (QG16, QG18 engine) DATA LINK CONNECTOR DISTRIBUTOR (CAMSHAFT POSITION SENSOR) (GA16, SR20 engine) DISTRIBUTOR (GA16, SR20 engine) ECM (CD20 engine) ECM (Gasoline engine) HEATED OXYGEN SENSOR 2 (REAR) (QG18, SR20 engine) (Type-1) HEATED OXYGEN SENSOR 2 (REAR) (QG16, QG18 engine) (Type-2) HEATED OXYGEN SENSOR 2 (REAR) (SR20 engine) (Type-2) IACV-FICD SOLENOID VALVE (GA16 engine) IGNITION COIL NO. 1 (QG16, QG18 engine) IGNITION COIL NO. 2 (QG16, QG18 engine) IGNITION COIL NO. 3 (QG16, QG18 engine) IGNITION COIL NO. 4 (QG16, QG18 engine) PARK/NEUTRAL POSITION (PNP) SWITCH (M/T models) PARK/NEUTRAL POSITION (PNP) SWITCH (CVT models) SHIELD WIRE (CAMSHAFT POSITION SENSOR) (QG18 engine) (If so equipped) SHIELD WIRE (CRANKSHAFT POSITION SENSOR) (QG18 engine) (If so equipped) SHIELD WIRE (CRANKSHAFT POSITION SENSOR) (SR20 engine) SHIELD WIRE (DISTRIBUTOR) (GA16, SR20 engine) (If so equipped) SHIELD WIRE (HEATED OXYGEN SENSOR) (GA16 engine) SHIELD WIRE (HEATED OXYGEN SENSOR 1 (FRONT)) (QG18, SR20 engine) (If so equipped) SHIELD WIRE (HEATED OXYGEN SENSOR 2 (REAR) (QG18, SR20 engine) (If so equipped) SHIELD WIRE (MASS AIR FLOW SENSOR) (Gasoline engine) (If so equipped) SHIELD WIRE (THROTTLE POSITION SENSOR) (Gasoline engine) (If so equipped) TCM (TRANSMISSION CONTROL MODULE)

EL-25

CONN. F95 F94 F88 M59

CELL CODE EC-PHASE EC-IGN/SG EC-POS EC-MIL/DL

F33

EC-CMPS

F33 F116 F101

EC-IGN/SG EC-MAIN EC-MAIN

F76

EC-O2S2B1, EC-02HSB1

F123

EC-O2S2B1, EC-02HSB1

F117 F40 F89 F90 F91 F92 F28 F72

EC-O2S2B1, EC-02HSB1 EC-FICD, HA-A/C EC-IGN/SG EC-IGN/SG EC-IGN/SG EC-IGN/SG EC-PNP/SW EC-PNP/SW, EL-START

F95

EC-PHASE

F88

EC-POS

F83

EC-CKPS

F33

EC-CMPS

F34

EC-HO2S EC-O2S1B1, EC-O2H1B1, EC-FUEL

F34 F76

EC-O2S2B1, EC-O2H2B1

F38

EC-MAFS

F16

EC-TPS, AT-TPS

M78

AT-MAIN, AT-TPS

GROUND DISTRIBUTION GROUND B18/B27

CONNECT TO AUTO LEVEL CONTROL UNIT BACK-UP LAMP (Sedan) (LHD) BACK-UP LAMP (Sedan) (RHD) CD AUTO CHANGER CENTRAL UNLOCK/TRUNK OR BACK DOOR RELEASE SWITCH DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY REAR LH (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY REAR LH (UNLOCK SENSOR) (With power door lock) DOOR LOCK ACTUATOR ASSEMBLY REAR RH (UNLOCK SENSOR) (With super lock) DOOR LOCK ACTUATOR ASSEMBLY REAR RH (UNLOCK SENSOR) (With power door lock) DOOR MIRROR HEATER (DRIVER’S SIDE) (Type-1) DOOR MIRROR HEATER (DRIVER’S SIDE) (Type-2) DOOR MIRROR HEATER (PASSENGER SIDE) (Type-1) DOOR MIRROR HEATER (PASSENGER SIDE) (Type-2) EXTERNAL TRUNK RELEASE SWITCH (Sedan) FUEL PUMP (GA16, QG18, SR20 engine) FUEL LEVEL SENSOR UNIT HEADLAMP AIMING SWITCH (Type-1) HEADLAMP AIMING SWITCH (Type-2) HEATED SEAT LH HEATED SEAT RH HEATED SEAT SWITCH LH HEATED SEAT SWITCH RH KEY CYLINDER SWITCH (DRIVER’S SIDE) KEY CYLINDER SWITCH (PASSENGER SIDE) POWER SEAT POWER SOCKET (Wagon) POWER WINDOW MAIN SWITCH REAR FOG LAMP (LHD) (Sedan with type-1) REAR FOG LAMP (RHD) (Sedan with type-1) REAR WIPER MOTOR (Sedan) SIDE AIR BAG MODULE LH SIDE AIR BAG MODULE RH TRUNK ROOM LAMP SWITCH (Sedan)

CONN. B123 T13 T8 B47 B121

EL-S/LOCK, EL-MULTI, EL-THEFT

D26

EL-D/LOCK, EL-MULTI, EL-THEFT

D16

EL-S/LOCK, EL-MULTI, EL-THEFT

D27

EL-D/LOCK, EL-MULTI, EL-THEFT

D21

EL-THEFT, EL-MULTI

D28

EL-MULTI, EL-THEFT

D25

EL-THEFT, EL-MULTI

D29

EL-MULTI, EL-THEFT

D4 D31 D13 D30 T20 B30 B31 B106 E129 B21 B61 B104 B105 D9 D17 B22 B86 D5 T8 T13 B52 B142 B143

EL-DEF EL-DEF EL-DEF EL-DEF EL-S/LOCK, EL-D/LOCK EC-F/PUMP EL-METER, EL-WARN EL-H/AIM, EL-ILL EL-H/AIM, EL-ILL EL-HSEAT EL-HSEAT EL-HSEAT EL-HSEAT EL-S/LOCK, EL-THEFT, EL-D/LOCK EL-S/LOCK, EL-D/LOCK EL-SEAT EL-HORN EL-WINDOW EL-R/FOG EL-R/FOG EL-WIP/R RS-SRS RS-SRS EL-INT/L, EL-WARN, EL-THEFT, ELMULTI EL-THEFT

B102

EL-26

EL-S/LOCK, EL-D/LOCK

D7

T10

ULTRA SONIC CANCEL SWITCH

CELL CODE EL-H/AIM EL-BACK/L EL-BACK/L EL-AUDIO

GROUND DISTRIBUTION GROUND B48/D110

CONNECT TO BACK-UP LAMP (Hatchback) (LHD) BACK-UP LAMP (Hatchback) (RHD) EXTERNAL BACK DOOR RELEASE SWITCH (Hatchback) HIGH-MOUNTED STOP LAMP (Hatchback) HIGH-MOUNTED STOP LAMP (Wagon) LICENSE PLATE LAMP LH (Hatchback with type-1) LICENSE PLATE LAMP LH (Hatchback with type-2) LICENSE PLATE LAMP LH (Wagon) LICENSE PLATE LAMP RH (Hatchback with type-1) LICENSE PLATE LAMP RH (Hatchback with type-2) LICENSE PLATE LAMP RH (Wagon) LUGGAGE ROOM LAMP SWITCH (Hatchback) (Wagon)

B65 B72 B119 B150/B151

REAR COMBINATION LAMP LH (BACK-UP LAMP) (Wagon for LHD) REAR COMBINATION LAMP LH (REAR FOG LAMP LH) (with type-1) REAR COMBINATION LAMP LH (STOP LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP LH (TAIL LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP LH (TURN SIGNAL) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (BACK-UP LAMP) (Wagon for RHD) REAR COMBINATION LAMP RH (REAR FOG LAMP RH) (with type-1) REAR COMBINATION LAMP RH (STOP LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (TAIL LAMP) (Hatchback) (Wagon) REAR COMBINATION LAMP RH (TURN SIGNAL) (Hatchback) (Wagon) REAR FOG LAMP (LHD) (Hatchback) REAR FOG LAMP (RHD) (Hatchback) REAR WINDOW DEFOGGER (Hatchback) REAR WINDOW DEFOGGER (Wagon) REAR WIPER MOTOR (Hatchback) (Wagon) SHIELD WIRE (SATELLITE SENSOR LH) (with type-1) SHIELD WIRE (SATELLITE SENSOR LH) (with type-2) SHIELD WIRE (SATELLITE SENSOR RH) REAR WINDOW DEFOGGER (Sedan) LICENSE PLATE LAMP LH (Sedan with type-2) LICENSE PLATE LAMP RH (Sedan with type-2) REAR COMBINATION LAMP LH (STOP LAMP) (Sedan with type-2) REAR COMBINATION LAMP LH (TAIL LAMP) (Sedan with type-2) REAR COMBINATION LAMP LH (TURN SIGNAL) (Sedan with type-2) REAR COMBINATION LAMP RH (STOP LAMP) (Sedan with type-2) REAR COMBINATION LAMP RH (TAIL LAMP) (Sedan with type-2) REAR COMBINATION LAMP RH (TURN SIGNAL) (Sedan with type-2)

EL-27

CONN. D108 B134 D117 D114 B85 B127 B149 D106 B128 B148 D116 D105

CELL CODE EL-BACK/L EL-BACK/L EL-S/LOCK, EL-D/LOCK EL-STOP EL-STOP EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-TAIL/L EL-INT/L, EL-WARN, EL-THEFT, ELMULTI

D104

EL-BACK

D104

EL-R/FOG

B46

EL-STOP

B46

EL-TAIL/L

B46

EL-TURN, EL-THEFT

D108

EL-BACK/L

D108

EL-R/FOG

B49

EL-STOP

B49

EL-TAIL/L

B49

EL-TURN, EL-THEFT

B135 D119 B41 D113 D107 B70 B137 B71 B120 B149 B148

EL-R/FOG EL-R/FOG EL-DEF EL-DEF EL-WIP/R RS-SRS RS-SRS RS-SRS EL-DEF EL-TAIL/L EL-TAIL/L

B145

EL-STOP

B145

EL-TAIL/L

B145

EL-TURN, EL-THEFT

B152

EL-STOP

B152

EL-TAIL/L

B152

EL-TURN, EL-THEFT

GROUND DISTRIBUTION GROUND T3/T4

CONNECT TO LICENSE PLATE LAMP LH (Sedan with type-1) LICENSE PLATE LAMP RH (Sedan with type-1) REAR COMBINATION LAMP LH (STOP LAMP) (Sedan with type-1) REAR COMBINATION LAMP LH (TAIL LAMP) (Sedan with type-1) REAR COMBINATION LAMP LH (TURN SIGNAL) (Sedan with type-1) REAR COMBINATION LAMP RH (STOP LAMP) (Sedan with type-1) REAR COMBINATION LAMP RH (TAIL LAMP) (Sedan with type-1) REAR COMBINATION LAMP RH (TURN SIGNAL) (Sedan with type-1)

EL-28

CONN. T9 T19

EL-TAIL/L EL-TAIL/L

CELL CODE

T2

EL-STOP

T2

EL-TAIL/L

T2

EL-TURN, EL-THEFT

T5

EL-STOP

T5

EL-TAIL/L

T5

EL-TURN, EL-THEFT

BATTERY CAUTION: ● If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. ● After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. ● Never add distilled water through the hole used to check specific gravity.

How to Handle Battery

Keep clean and dry.

METHODS OF PREVENTING OVER-DISCHARGE The following precautions must be taken to prevent over-discharging a battery. ● The battery surface (particularly its top) should always be kept clean and dry. ● The terminal connections should be clean and tight. ● At every routine maintenance, check the electrolyte level. SEL711E Remove negative terminal.

●

When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.)

●

Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent overdischarge.

SEL712E Hydrometer

Thermometer

SEL459R

CHECKING ELECTROLYTE LEVEL WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.

EL-29

BATTERY How to Handle Battery (Cont’d) ● ●

Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.

Cell plug

“MAX” level “MIN” level

SEL001K

SULPHATION Normal battery Sulphated battery Charging voltage Charging voltage

Charging current Charging current

A battery will be completely discharged if it is left unattended for a long time and the specific gravity becomes less than 1.100. This may result in sulphation on the cell plates. To find if a discharged battery has been “sulphated”, pay attention to its voltage and current when charging it. As shown in the figure at left, if the battery has been “sulphated”, less current and higher voltage may be observed in the initial stage of charging.

Duration of charge SEL005Z

Read top level with scale

Hydrometer

SPECIFIC GRAVITY CHECK 1. Read hydrometer and thermometer indications at eye level.

Thermometer

SEL442D

● Hydrometer

When electrolyte level is low, tilt battery case for easy measurement.

Thermal gauge

SEL006Z

EL-30

BATTERY How to Handle Battery (Cont’d) 2. Convert into specific gravity at 20°C (68°F). Example: ● When electrolyte temperature is 35°C (95°F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20°C (68°F) is 1.240. ● When electrolyte temperature is 0°C (32°F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C (68°F) is 1.196.

Specific gravity at electrolyte temperature

Converted specific gravity

.

Freezing zone

(−22)

(−4)

(14) (32) (50) (68) Electrolyte temperature °C (°F)

EL-31

(86)

(104)

(122) SEL007Z

BATTERY Battery Test and Charging Chart Chart I

VISUAL INSPECTION ● Check battery case for cracks or bends. ● Check battery terminals for damage. ● If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK. OK

왔

왔

Replace battery.

CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.

왔

왔

Below 1.100

왔

SLOW CHARGE Refer to “A: Slow Charge”.

왔

1.100 - 1.220

*

Above 1.220

QUICK CHARGE Refer to “C: Quick Charge”.

STANDARD CHARGE Refer to “B: Standard Charge”.

Ready for use ● Mount battery again and check loose terminals. Also check other related circuits.

CAPACITY TEST Refer to “Chart II”.

CAPACITY TEST Refer to “Chart II”. NG

OK

Ready for Replace use battery.

Ready for use

왔

왔

NG 왔

왔

CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.

QUICK CHARGE Refer to “C: Quick Charge”. ● Time required: 45 min.

왔

왔

RECHARGE Refer to “C: Quick Charge”. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).

Ready for use

OK

Ready for use

CAPACITY TEST Refer to “Chart II”. OK

CAPACITY TEST Refer to “Chart II”.

왔

왔

왔

왔

NG

왔

왔

OK

CAPACITY TEST Refer to “Chart II”. OK

왔

왔

왔

왔 왔

NG

NG

Replace battery.

* “STANDARD CHARGE” is recommended if the vehicle is in storage after charging.

EL-32

NG

왔

Replace battery.

BATTERY Battery Test and Charging Chart (Cont’d) Check battery type and determine the specified current using the following table. Fig. 1 DISCHARGING CURRENT (Load Tester) ●

Chart II

CAPACITY TEST

왔

왔

Test using battery checker.

Test using load tester.

왔

왔

Follow manufacturer’s instructions to check and determine if battery is serviceable. OK 왔

Ready for use

NG

Type (YUASA type code)

Current (A)

025

240

027

285

096

375

063

210

065

255

075

300

Read load tester voltage when specified discharging current (Refer to Fig. 1.) flows through battery for 15 seconds.

왔

Go to next step.

왔

Above 9.6 volts

왔

Below 9.6 volts

OK 왔

Ready for use

NG 왔 SEL008Z

Go to next step.

EL-33

BATTERY Battery Test and Charging Chart (Cont’d) A: SLOW CHARGE

Determine initial charging current from specific gravity referring to Fig. 2. Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)

왔 ● ●

Charge battery. Check charging voltage 30 minutes after starting the battery charge.

CONVERTED SPECIFIC GRAVITY Below 1.100 ●

왔

왔

●

Below 12 volts or above 15 volts

12 to 15 volts OK

BATTERY TYPE (YUASA type code) 025

027

096

063

065

075

7.0 (A)

7.0 (A)

8.5 (A)

8.0 (A)

10.0 (A)

10.0 (A)

Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.

NG 왔

왔

Fig. 3 ADDITIONAL CHARGE (Slow charge)

Replace battery.

Continue to charge for 12 hours.

Below 1.150

왔

왔

CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.

왔

Charge for 5 hours at initial charging current setting.

1.150 - 1.200

1.200 - 1.240

왔

Above 1.240

왔

Charge for 4 hours at initial charging current setting.

Charge for 2 hours at initial charging current setting.

Conduct additional charge as per Fig. 3, if necessary. 왔

왔

왔

왔

왔

Go to “CAPACITY TEST”.

왔

Go to “CAPACITY TEST”.

CAUTION: ● Set charging current to value specified in Fig. 2. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). ● Remove cell caps during charging.

EL-34

BATTERY Battery Test and Charging Chart (Cont’d) B: STANDARD CHARGE

Determine initial charging current from specific gravity, referring to Fig. 4.

왔

Charge battery for 8 hours.

Fig. 4 INITIAL CHARGING CURRENT SETTING (Standard charge)

025

027

096

063

065, 075

1.100 - 1.130

6.0 (A)

6.0 (A)

7.5 (A)

7.0 (A)

9.0 (A)

1.130 - 1.160

5.0 (A)

5.0 (A)

6.0 (A)

6.0 (A)

8.0 (A)

1.160 - 1.190

4.0 (A)

4.0 (A)

5.0 (A)

5.0 (A)

7.0 (A)

1.190 - 1.220

3.0 (A)

3.0 (A)

4.0 (A)

4.5 (A)

5.0 (A)

● ●

왔

CHECKING SPECIFIC GRAVITY Refer to “Specific Gravity Check”.

왔

Conduct additional charge as per Fig. 5, if necessary.

왔

Go to “CAPACITY TEST”.

BATTERY TYPE (YUASA type code)

CONVERTED SPECIFIC GRAVITY

Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.

Fig. 5 ADDITIONAL CHARGE (Standard charge) Below 1.150

왔

1.150 - 1.200

1.200 - 1.240

왔

Charge for 3.5 hours at initial charging current setting. 왔

Above 1.240

왔

Charge for 2.5 hours at initial charging current setting.

Charge for 1.5 hours at initial charging current setting.

왔

왔

왔

왔

Go to “CAPACITY TEST”.

CAUTION: ● Do not use standard charge method on a battery whose specific gravity is less than 1.100. ● Set charging current to value specified in Fig. 4. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). ● Remove cell caps during charging.

EL-35

BATTERY Battery Test and Charging Chart (Cont’d) C: QUICK CHARGE Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge) BATTERY TYPE (YUASA type code)

Determine initial charging current setting and charging time from specific gravity, referring to Fig. 6.

025, 027, 063

096, 065, 075

20 (A)

25 (A)

CONVERTED SPECIFIC GRAVITY

CURRENT [A]

왔

Charge battery.

왔

Go to “CAPACITY TEST”.

● ●

1.100 - 1.130

2.5 hours

1.130 - 1.160

2.0 hours

1.160 - 1.190

1.5 hours

1.190 - 1.220

1.0 hours

Above 1.220

0.75 hours (45 min.)

Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.

CAUTION: ● Do not use quick charge method on a battery whose specific gravity is less than 1.100. ● Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation. If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). ● Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery.

Service Data and Specifications (SDS)

Applied model

Type (YUASA type code) Capacity

V-AH

CCA

EL-36

SR engine SR with CVT engine (cold with CVT area) (stanCD dard) engine (standard)

QG engine (standard)

QG engine (cold area) SR engine with MT (standard)

SR engine with MT (cold area

CD engine (cold area)

025

027

063

065

075

096

12 - 61

12 - 61

12 - 47

12 - 55

12 - 50

12 - 75

480

570

420

510

600

750

STARTING SYSTEM Wiring Diagram — START — GASOLINE ENGINE MODELS WITH M/T BATTERY Refer to EL-POWER.

: With GA engine and QG engine for Nordic : Except : With GA engine ST

OFF

IGNITION SWITCH

ON

: With QG engine : With SR engine or QG engine

ACC

STARTER MOTOR

BATTERY

YEL128C

EL-37

STARTING SYSTEM Wiring Diagram — START — (Cont’d) GASOLINE ENGINE MODELS WITH CVT

YEL999C

EL-38

STARTING SYSTEM Wiring Diagram — START — (Cont’d) DIESEL ENGINE MODELS BATTERY

Refer to EL-POWER.

ST

OFF

IGNITION SWITCH

ON ACC

STARTER MOTOR BATTERY

YEL130C

EL-39

STARTING SYSTEM Trouble Diagnoses If any abnormality is found, immediately disconnect battery negative terminal. Starter does not stop.

왘

Replace magnetic switch.

왘

Does engine turn normally?

Engine does not start. 왔

Does engine turn by cranking?

Yes

Yes

왘

Check ignition/fuel system.

왘

Repair starter motor.

왘

Check pinion clutch.

왘

Replace magnetic switch.

왘

Repair starter motor.

No (Turns slowly.)

No 왔

OK

Check battery as follows: ● Charging condition ● Terminal connections ● Terminal corrosion 왔

NG

A 쑗

왔

Does starter motor turn?

Yes

왘

Yes

Does gear shaft turn?

No

No 왔

Check reduction gear, armature and gear shaft. 왔

Check fuse and fusible link.

NG

왘

Replace.

OK 왔

Check battery as follows: ● Charging condition ● Terminal connections ● Terminal corrosion

A 쑗

NG

왔 왘

OK 왔

Check starting system wiring.

NG

● ●

Charge battery. Repair connections and corrosion of battery terminals.

왘

Repair.

왘

Replace magnetic switch

왘

Does starter turn under no load by connecting wires as follows?

OK 왔

Does magnetic switch operation sound occur?

No

Yes 왔

Check condition of pinion and ring gear mesh.

OK

Yes

NG 왔 ● ● ●

No

Adjust pinion movement. Check pinion moving mechanism. Check ring gear. SEL009Z

EL-40

STARTING SYSTEM Construction Internal gear

SEC. 233 S114-806A

Through-bolts Packing

4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.40)

7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8) Magnetic switch assembly Center bracket (P) Dust cover kit

Planetary gear

Shift lever set

Pinion shaft

Gear case assembly

Thrust washer

E-ring

Rear cover assembly Thrust washer Brush spring

Pinion assembly Pinion stopper

. .

Brush

Brush

(-)

Brush assembly

(+)

Armature assembly 6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)

Yoke assembly

N·m (kg-m, in-lb) High-temperature grease point

Center bracket (A) MEL675EB

SEC. 233 S114-871

Internal gear Through-bolts Packing 7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8) Magnetic switch assembly

4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.40)

Center bracket (P) Dust cover kit Shift lever set

Planetary gear

Pinion shaft Gear case assembly

E-ring

Thrust washer

Rear cover assembly Thrust washer

Pinion assembly Pinion stopper

Brush spring Brush (-) Brush (+)

Brush assembly

Armature assembly 6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)

Yoke assembly

: N·m (kg-m, in-lb) : High-temperature grease point

Center bracket (A)

EL-41

YEL420B

STARTING SYSTEM Construction (Cont’d) SEC. 233 S114-800B

쑗4

쑗3

4.9 - 6.4 (0.50 - 0.65, 43.4 - 56.4)

쑗2 쑗1 쑗5 쑗6

쑗8 13 쑗 10 쑗

쑗7

1.7 - 2.4 (0.17 - 0.24, 14.8 - 20.8)

쑗9

11 쑗

14 쑗 12 쑗

6.4 - 8.3 (0.65 - 0.85, 56.4 - 73.8)

: N·m (kg-m, in-lb) : High-temperature grease point YEL421B

1 쑗 2 쑗 3 쑗 4 쑗 5 쑗

Shift lever Adjusting plate Magnetic switch assembly Internal gear Planetary gear

6 쑗 7 쑗 8 쑗 9 쑗 10 쑗

Pinion shaft Rear cover Brush spring Brush (−) Brush (+)

EL-42

11 쑗 12 쑗 13 쑗 14 쑗

Armature Yoke Pinion assembly Gear case

STARTING SYSTEM Construction (Cont’d) SEC. 233 M70R

8 (0.8, 69)

: N·m (kg-m, in-lb) YEL422B

1 쑗 2 쑗 3 쑗 4 쑗 5 쑗

Magnetic switch assembly Shift lever assembly Gear case Pinion assembly Pinion shaft assembly

6 쑗 7 쑗 8 쑗 9 쑗 10 쑗

Planetary gear assembly Centre bracket Armature Pinion stopper Yoke assembly

EL-43

11 쑗 12 쑗 13 쑗 14 쑗

Brush holder Rear cover Drain hose Through-bolts

STARTING SYSTEM Construction (Cont’d) SEC. 233 S13 - 305

6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)

7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8)

N·m (kg-m, in-lb) High-temperature grease point

NEL299

1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗 7 쑗

Bearing retainer Pinion shaft Clutch assembly Return spring Pinion stopper Stopper clip Gear case

8 쑗 9 쑗 10 쑗 11 쑗 12 쑗 13 쑗 14 쑗

Adjusting plates Torsion spring Shift lever Magnetic switch assembly Armature assembly Field coil Yoke

EL-44

15 쑗 16 쑗 17 쑗 18 쑗 19 쑗 20 쑗

Brush (+) Brush spring Brush (−) Brush holder Rear cover Through-bolt

STARTING SYSTEM Construction (Cont’d) SEC. 233 M2M62071

4.9 - 6.9 (0.50 - 0.70, 43.4 - 60.8)

3.9 - 7.8 (0.40 - 0.80, 34.7 - 69.4)

2.5 - 4.4 (0.25 - 0.45, 21.7 - 39.1) N·m (kg-m, in-lb) MEL780DB 1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗

Pinion stopper Pinion assembly Gear case Pinion shaft assembly Shift lever Spring

7 쑗 8 쑗 9 쑗 10 쑗 11 쑗 12 쑗

Holder Reduction gear Washer Center bracket Magnetic switch assembly Armature

13 쑗 14 쑗 15 쑗 16 쑗 17 쑗 18 쑗

Yoke Brush (+) Brush spring Brush (-) Brush holder Rear cover

MEL232M

EL-45

STARTING SYSTEM Construction (Cont’d) SEC. 233 S13-531

6.4 - 7.8 (0.65 - 0.80, 56.4 - 69.4)

7.4 - 9.8 (0.75 - 1.00, 65.1 - 86.8)

N·m (kg-m, in-lb) High temperature grease point

MEL233FB

1 쑗 2 쑗 3 쑗 4 쑗 5 쑗 6 쑗 7 쑗

Bearing retainer Pinion shaft Clutch assembly Return spring Pinion stopper Stopper clip Gear case

8 쑗 9 쑗 10 쑗 11 쑗 12 쑗 13 쑗 14 쑗

Dust cover Torsion spring Shift lever Magnetic switch assembly Armature assembly Field coil Yoke

EL-46

15 쑗 16 쑗 17 쑗 18 쑗 19 쑗 20 쑗

Brush (+) Brush spring Brush (−) Brush holder Rear cover Through-bolt

STARTING SYSTEM : N·m (kg-m, ft-lb)

Removal and Installation Removal 1. 2. 3. 4. 5. 6. 7.

36 - 48 (3.7 - 4.9, 26.6 - 35.4)

NEL301

Remove battery negative cable from battery. Remove intake air duct. Remove starter motor mounting bolts. Remove battery cable from starter motor. Disconnect harness connector from starter motor harness. Remove intake manifold support bracket. Remove starter motor from under the vehicle.

Installation ●

Installation is reverse order of removal.

YEL947C

Inspection Type 1

MAGNETIC SWITCH CHECK “M” terminal

Before starting to check, disconnect battery ground cable. Disconnect “M” terminal of starter motor. 1. Continuity test (between “S” terminal and switch body). ● No continuity ... Replace. 2. Continuity test (between “S” terminal and “M” terminal). ● No continuity ... Replace. ● ●

Type 2

“M” terminal

NEL302

EL-47

STARTING SYSTEM Inspection (Cont’d) PINION/CLUTCH CHECK 1. Inspect pinion teeth. ● Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) 2. Inspect reduction gear teeth. ● Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) 3. Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. ● If it locks or rotates in both directions, or unusual resistance is evident. ... Replace.

Type 1

Type 2

NEL303

BRUSH CHECK Brush cap and lever Check wear of brush. Wear limit length: Refer to SDS (EL-52). ● Excessive wear ... Replace.

Vernier caliper Brush

SEL014Z

Brush Spring Pressure

Brush spring

Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush): Refer to SDS (EL-52). ● Not within the specified values ... Replace.

Brush

SEL015Z

Brush Holder

Type 1

1. Perform insulation test between brush holder (positive side) and its base (negative side). ● Continuity exists. ... Replace. 2. Check brush to see if it moves smoothly. ● If brush holder is damaged or deformed, replace it; clear sliding surface if dirty.

NEL304

EL-48

STARTING SYSTEM Inspection (Cont’d) Type 1

YOKE CHECK Magnet Holder

Magnet is secured to yoke by bonding agent. Check magnet to see that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly. Holder may move slightly as it is only inserted and not bonded. CAUTION: Do not clamp yoke in a vice or strike it with a hammer.

Type 2 Magnet

SEL018Z

ARMATURE CHECK 1. Continuity test (between two segments side by side). ● No continuity ... Replace. 2. Insulation test (between each commutator bar and shaft). ● Continuity exists. ... Replace.

SEL019Z

3. Check commutator surface. ● Rough ... Sand lightly with No. 500 - 600 emery paper.

Emery paper SEL020Z

4. Check diameter of commutator. Commutator minimum diameter: Refer to SDS (EL-52). ● Less than specified value ... Replace. Vernier caliper

Commutator SEL021Z

EL-49

STARTING SYSTEM Inspection (Cont’d) M70R 5. Check depth of insulating mica from commutator surface. ● Less than 0.3 mm (0.012 in) ... Replace.

0,3 mm (0,012 in)

SEL207P

S13-305, S13-531, S114-800B, S114-806A, S114-871, M2M62071, 0 001 116 006 6. Check depth of insulating mold from commutator surface. ● Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in) Round

0.5 - 0.8 mm (0.020 - 0.031 in)

Correct

File

Commutator

Segment Mold

Incorrect SEL022Z

EL-50

STARTING SYSTEM Assembly Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the starter. Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT Pinion stopper

Clearance “l” With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance “l” between the front edge of the pinion and the pinion stopper. Clearance “l”: Refer to SDS (EL-52).

Clearance “l” SEL026Z

Movement “
” Compare movement “
” in height of pinion when it is pushed out with magnetic switch energized and when it is pulled out by hand until it touches stopper. Movement “
” Refer to SDS (EL-52).

SEL497D

●

Not in the specified value ... Adjust by selecting the correct adjusting plate.

Adjusting plate

NEL305

EL-51

STARTING SYSTEM Service Data and Specifications (SDS) STARTER

Type

M70R

M2T62071

0 001 116 006

MAGNETI MARELLI

MITSUBISHI

BOSCH

Reduction gear type

Reduction gear type

Non-Reduction

SR20

CD20T

QG18 QG16

Applied model System voltage

V

12

No load Terminal voltage

V

11.5

11.0

11.5

Current

A

115

Less than 105

Less than 48

rev/min

More than 4500

More than 4,030

More than 5,800

Min. commutator dia.

mm (in)

28.8 (1.134)

31.4 (1.236)

33.5 (1.319)

Min. brush of length

mm (in)

5.0 (0.197)

11.5 (0.453)

3.5 (0.138)

14.3 - 25.2 (1.46 - 2.57, 3.22 - 5.69)

13.7 - 25.5 (1.4 - 2.6, 3.1 - 5.7)

5.2 (0.53, 1.17) at 7.5 mm (0.295 in) brush length

Movement “
” in height of pinion assembly mm (in)

—

—

—

Clearance “I” between pinion front edge & pinion stopper mm (in)

0 - 3.0 (0 - 0.118)

—

0.0 - 3.9 (0 - 0.154)

Revolution

Brush spring tension

N (kg, lb)

S114-806A

S114-871

Type

S13-305

S13-531

S114-800B

CD20T cold area

QG18⋅QG16 cold area

HITACHI Reduction gear type

Applied model System voltage

SR20 with CVT models

SR20

CD20T

V

12

V

11.0

No load Terminal voltage Current Revolution

A rev/min

Less than 90 More than 2,700

More than 2,300

Less than 140

Less than 90

More than 3900

More than 2750

Min. commutator dia.

mm (in)

28.0 (1.102)

35.5 (1.398)

28.0 (1.102)

Min. brush length

mm (in)

10.5 (0.413)

11.0 (0.433)

10.5 (0.413)

28.4 - 34.3 (2.90 - 3.50, 6.39 - 7.72)

12.7 - 17.7 (1.29 - 1.80, 2.84 - 3.97)

Brush spring tension

N (kg, lb)

16.2 (1.65, 3.64)

12.7 - 17.7 (1.29 1.80, 2.84, 3.97)

Clearance between bearing & armature shaft mm (in) Clearance “I” between pinion front edge & pinion stopper mm (in)

Less than 0.2 (0.008) 0.3 - 2.5 (0.012 - 0.098)

0.3 - 2.0 (0.012 - 0.079)

EL-52

0.3 - 0.8 (0.012 - 0.031)

0.3 - 2.5 (0.012 - 0.098)

CHARGING SYSTEM Wiring Diagram — CHARGE — GASOLINE ENGINE MODELS

YEL001D

EL-53

CHARGING SYSTEM Wiring Diagram — CHARGE — (Cont’d) DIESEL ENGINE MODELS

YEL002D

EL-54

CHARGING SYSTEM Trouble Diagnoses Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table. ● Before starting, inspect the fusible link. ● Use fully charged battery.

WITH IC REGULATOR

Ignition switch “ON”

Warning lamp “OFF”

Disconnect connector (S, L) and ground L harness side.

Check the following: ⋅ Warning lamp bulb ⋅ Fuse for warning lamp

Warning lamp “OFF”

Warning lamp “ON”

Damaged IC regulator. Replace.

Warning lamp “ON” Engine start. Engine speed: 1,500 rpm

Warning lamp “ON”

Warning lamp “OFF”

OK

Check the following: ⋅ Drive belt ⋅ Fuse for S terminal ⋅ Connector (S, L terminal) connection

Engine idling

Warning lamp “OFF”

OK

More than 15.5V

Damaged IC regulator. Replace.

No generation

Field circuit is open.

Warning lamp “ON” Engine speed: 1,500 rpm (Measured B terminal voltage)

Warning lamp: “CHARGE” warning lamp in combination meter

Note: ● If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.) ● When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty parts with new ones.

MALFUNCTION INDICATOR The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following symptoms occur while alternator is operating: ● Excessive voltage is produced. ● No voltage is produced.

EL-55

CHARGING SYSTEM Construction SEC. 231 LR190-734E

쑗7

쑗5

3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)

쑗6 7.8 - 10.8 (0.80 - 1.10, 69.4 - 95.5)

3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)

쑗2

쑗3

10 쑗

쑗4

쑗1 3.14 - 3.9 (0.320 - 0.398, 27.8 - 34.5)

쑗9 63.7 - 83.3 (6.50 - 8.50, 46.99 - 61.44)

: N·m (kg-m, in-lb) : N·m (kg-m, ft-lb)

쑗8

NEL320

1 쑗 2 쑗 3 쑗 4 쑗

Pulley assembly Front cover Front bearing Retainer

5 쑗 6 쑗 7 쑗

8 쑗 9 쑗 10 쑗

Rotor Slip ring Stator

EL-56

IC voltage regulator assembly Diode assembly Rear cover

CHARGING SYSTEM Construction (Cont’d) SEC. 231 A2TB3691 A2TB3891 12.8 - 18.6 (1.3 - 1.9, 10 - 13) 3.5 - 5.3 (0.36 - 0.54, 31.0 - 46.9) 2.0 - 5.3 (0.20 - 0.54, 17.7 - 46.9)

99 - 137 (10.1 - 12.9, 73 - 101)

2.0 - 5.3 (0.20 - 0.54, 17.7 - 46.9) : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) YEL427B

1 쑗 2 쑗 3 쑗 4 쑗

Pulley assembly Front cover Front bearing Bearing retainer

5 쑗 6 쑗 7 쑗

Rotor Rear bearing Stator

EL-57

8 쑗 9 쑗 10 쑗

IC voltage regulator assembly Diode assembly Rear cover

CHARGING SYSTEM Construction (Cont’d)

MEL141LA

EL-58

CHARGING SYSTEM Construction (Cont’d) SEC. 231 A115I-80A 8 쑗

70 - 90 (7.1 - 9.2, 51.6 - 66.4)

3.5 - 5.5 (0.36 - 0.56, 31 - 49) 9 쑗 10 쑗

7 쑗

쑗1

4 쑗

6-8 (0.6 - 0.8, 53 - 71)

3 쑗

5 쑗

11 쑗

6 쑗

2 쑗

3-4 (0.3 - 0.4, 27 - 35) : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) YEL429B

1 쑗 2 쑗 3 쑗 4 쑗

Pulley assembly Front cover Front bearing Bearing retainer

5 쑗 6 쑗 7 쑗 8 쑗

Stator Rotor Special bolt Rear cover

EL-59

9 쑗 10 쑗 11 쑗

Diode assembly Brush holder Dust cover

CHARGING SYSTEM Removal and Installation Loosen

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

Adjusting bolt

Tighten

Lock bolt

.

NEL327

: N·m (kg-m, ft-lb)

16 - 21 (1.6 - 2.1, 12 - 15)

Loosen lock bolt. Remove RH undertray. Loosen alternator mounting bolt and remove drive belt. Remove lock bolt and adjust. Remove harness connectors. Remove alternator mounting bolt. Support engine with jack, and remove front engine mounting bolt. 8. Remove alternator.

Disassembly REAR COVER CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly.

37 - 50 (3.8 - 5.1, 27 - 37)

37 - 50 (3.8 - 5.1, 27 - 37) SEL910T

REAR BEARING CAUTION: ● Do not reuse rear bearing after removal. Replace with a new one. ● Do not lubricate rear bearing outer race. Soldering iron (200W capacity) Bearing box

SEL032Z

Inspection ROTOR CHECK

Slip rings SEL033Z

1. Resistance test Resistance: Refer to SDS (EL-63). ● Not within the specified values ... Replace rotor. 2. Insulator test ● Continuity exists ... Replace rotor. 3. Check slip ring for wear. Slip ring minimum outer diameter: Refer to SDS (EL-63). ● Not within the specified values ... Replace rotor.

EL-60

CHARGING SYSTEM Inspection (Cont’d) BRUSH CHECK

Type 1

1. Check smooth movement of brush. ● Not smooth ... Check brush holder and clean. 2. Check brush for wear. ● Replace brush if it is worn down to the limit line.

Brush wear limit line

Type 2 Brush wear limit line

SEL034Z

STATOR CHECK

Type 1

1. Continuity test ● No continuity ... Replace stator. 2. Ground test ● Continuity exists ... Replace stator.

Lead wire

Type 2

SEL037Z

EL-61

CHARGING SYSTEM Amount of protrusion: Fix ring at the position of minimum protrusion. Ring

Assembly RING FITTING IN REAR BEARING Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible. CAUTION: Do not reuse rear bearing after removal. ●

Eccentric groove

Rear bearing SEL044Z

REAR COVER INSTALLATION (1) Fit brush assembly, diode assembly, regulator assembly and stator. (2) Push brushes up with fingers and install them to rotor. Take care not to damage slip ring sliding surface.

SEL048Z

SEL049Z

EL-62

CHARGING SYSTEM Service Data and Specifications (SDS) ALTERNATOR Type

A2TB3691

A2TB3891

LR180-762

LR190-734E

MITSUBISHI Applied model Nominal rating

V-A

HITACHI

SR20, MT

SR20, CVT

QG18, QG16

CD20T

12-80

12-90

12-80

12-90

Ground polarity

Negative

Minimum revs under noload (When 13.5V is applied) rev/min

Less than 1,300

Hot output current More than 23/1,300 (when 13.5V is applied) More than 64/2,500 A/rev/min More than 82/5,000

Less then 1,000

More than 22/1,300 More than 64/2,500 More than 85/5,000

Regulated output voltage

More than 23/1,300 More than 65/2,500 More than 87/5,000

More than 32/1,300 More than 54/2,500 More than 87/5,000

14.1 - 14.7 V

Brush minimum length mm (in)

5.0 (0.197)

6.0 (0.236)

Brush spring pressure N (g, oz)

4.8 - 6.0 (490 - 610, 17.28 - 21.51)

1.0 - 3.43 (102 - 350, 3.60 - 12.34)

Slip ring minimum diameter mm (in)

22.1 (0.870)

26.0 (1.024)

Rotor coil resistance at 20°C (68°F)

2.2 - 2.6

1.8 - 2.1

EL-63

2.67

2.60

COMBINATION SWITCH Combination Switch/Check FOG

TURN

FRONT WIPER AND WASHER

INT

MIST

WASH (Rear)

FR and RR

LIGHT

REAR WIPER AND WASHER

FR or RR

2ND

TRIP COMPUTER

OFF

OFF

OFF ON

OFF 1ST

VOLUME

WASH (Front)

OFF

INT

LO

HI

(Light)

(Wiper)

LIGHTING SWITCH (With rear fog lamp) OFF 2ND 1ST

(Wiper)

WIPER AND WASHER SWITCH FOG LAMP SWITCH OFF REAR

FRONT MIST OFF INT LO

HI

FR/WASH

WASH OFF RR/WASH

OFF

REAR INT ON

TRIP INT ON

LIGHTING SWITCH (With front and rear fog lamp) OFF

1ST

2ND WIPER AMP.

FOG LAMP SWITCH FR AND RR OFF FR

TURN SIGNAL SWITCH

INTERMITTENT WIPER VOLUME

YEL230C

EL-64

STEERING SWITCH Check

YEL954C

EL-65

STEERING SWITCH Replacement Wiper and washer switch Switch base Lighting switch

For removal and installation of spiral cable, refer to RS section [“Installation — Air Bag Module and Spiral Cable”, “SUPPLEMENTAL RESTRAINT SYSTEM (SRS)”]. ● Each switch can be replaced without removing combination switch base.

YEL903

●

To remove combination switch base, remove base attaching screw.

●

Before installing the steering wheel, align the steering wheel guide pins with the screws which secure the combination switch as shown in the left figure.

YEL904

Screw Combination switch

Steering wheel guide pin

SEL151V

EL-66

HEADLAMP (without Daytime Light System) — Conventional Type — Wiring Diagram — H/LAMP —

EL-H/LAMP-01

BATTERY

Refer to EL-POWER.

15A 31 : 32 :

GS

15A 32 :

GS

DI

33 :

DI

R/W

: With gasoline engine

DI

: With diesel engine

R

R/W

R

8

5

2ND

OFF

GS

2ND

OFF

1ST

COMBINATION SWITCH (LIGHTING SWITCH)

1ST PASS

PASS

PASS

LOW

PASS

PASS

PASS

LOW LOW HIGH

LOW

HIGH

HIGH

HIGH

10

9

7

6

R/Y

R/B

P/L

R/G

HIGH

HIGH

R/B

R/Y

R/B

P/L

R/G

3

1

3

1

HEADLAMP LH LOW

HIGH

E5

HIGH

2

2

B

B

B

B

B

E37

1 2 3

LOW

E5 GY

E111

LOW

LOW

A

Next page

HEADLAMP RH

E32

B

E11

, E32 GY

1 3 13 2 12 14 11 E111 9 6 5 7 8 10 W

YEL257B

EL-67

HEADLAMP (without Daytime Light System) — Conventional Type — Wiring Diagram — H/LAMP — (Cont’d)

YEL003D

EL-68

HEADLAMP (without Daytime Light System) — Conventional Type — Trouble Diagnoses Symptom LH headlamps do not operate.

Possible cause 1. Bulb 2. Grounds 3. 15A fuse

E11

and

E37

4. Lighting switch RH headlamps do not operate.

1. Bulb 2. Grounds 3. 15A fuse

E11

and

E37

4. Lighting switch

Repair order 1. Check bulb. 2. Check grounds E11 and E37 3. Check 15A fuse [No. 31 (gasoline engine), 32 (diesel engine) located in fuse and fusible link box]. Verify battery positive voltage is present at terminal 쑗 8 of lighting switch. 4. Check lighting switch. 1. Check bulb. 2. Check grounds E11 and E37 3. Check 15A fuse [No. 32 (gasoline engine), 33 (diesel engine) located in fuse and fusible link box]. Verify battery positive voltage is present at terminal 쑗 5 of lighting switch. 4. Check lighting switch.

LH high beams do not operate, but LH low beam operates.

1. Bulbs 1. Check bulbs. 2. Open in LH high beams circuit 2. Check R/B wire between lighting switch and LH headlamps for an open circuit. 3. Check lighting switch. 3. Lighting switch

LH low beam does not operate, but LH high beam operates.

1. Bulb 2. Open in LH low beam circuit 3. Lighting switch

1. Check bulb. 2. Check R/Y wire between lighting switch and LH headlamp for an open circuit. 3. Check lighting switch.

RH high beams do not operate, but RH low beam operates.

1. Bulbs 2. Open in RH high beams circuit 3. Lighting switch.

1. Check bulbs. 2. Check R/G wire between lighting switch and RH headlamps for an open circuit. 3. Check lighting switch.

RH low beam does not operate, but RH high beam operates.

1. Bulb 2. Open in RH low beam circuit

1. Check bulb. 2. Check P/L wire between lighting switch and RH headlamp for an open circuit. 3. Check lighting switch.

3. Lighting switch High beam indicator does not work.

1. Bulb 2. Grounds M6 , M26 and M28 or E11 and E39 3. Open in high beam circuit

EL-69

1. Check bulb in combination meter. 2. Check grounds M6 , M26 and M28 or E11 and E39 . 3. Check R/B wire between lighting switch and combination meter for an open circuit.

HEADLAMP (without Daytime Light System) — Conventional Type — Bulb cover Open Rubber cap

Lock

Push to remove

Bulb Replacement The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body. ● Grasp only the plastic base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Turn the bulb retaining ring counterclockwise until it is free from the headlamp reflector, and then remove it. 3. Disconnect the harness connector from the back side of the bulb. 4. Remove the headlamp bulb carefully. Do not shake or rotate the bulb when removing it. 5. Install in the reverse order of removal. CAUTION: Do not leave headlamp reflector without bulb for a long period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed.

SEL995K

Aiming Adjustment When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp tester. Aimers should be in good repair, calibrated and operated in accordance with respective operation manuals. If any aimer is not available, aiming adjustment can be done as follows: For details, refer to the regulations in your own country. a. Keep all tires inflated to correct pressures. b. Place vehicle and tester on one and same flat surface. c. See that there is no-load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other than the driver (or equivalent weight placed in driver’s position).

CAUTION: Be sure aiming switch is set to “0” when performing aiming adjustment on vehicles equipped with headlamp aiming control.

SEL466V

EL-70

HEADLAMP (without Daytime Light System) — Conventional Type — Aiming Adjustment (Cont’d) LOW BEAM 1. Turn headlamp low beam on. 2. Use adjusting screws to perform aiming adjustment. ● First tighten the adjusting screw all the way and then make adjustment by loosening the screw.

Left and right adjusting screw

Up and down adjusting screw

NEL548

Screen Vertical center line ahead of head lamps

Center of low beam bulb

300 (11.81) Basic illuminating area for adjustment

Horizontal center line of head lamps

Unit: mm (in)

33.5 (1.319)

Cut off line

Aiming allowable area

Screen

27.5 (1.083)

Cut off line

25,000 (984.25) NEL563

●

●

Adjust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration. Figure to the above shows headlamp aiming pattern for driving on left side of road; for driving on right side of road, aiming pattern is reversed.

EL-71

HEADLAMP (without Daytime Light System) — Xenon Type — System Description Xenon type headlamp is adopted to the low beam headlamps. Xenon bulbs do not use a filament. Instead, they produce light when a high voltage current is passed between two tungsten electrodes through a mixture of xenon (an insert gas) and certain other metal hallides. In addition to added lighting power, electronic control of the power supply gives the headlamps stable quality and tone color. Following are some of the many advantage of the xenon type headlamp. ● The light produced by the headlamps is white color approximating sunlight that is easy on the eyes. ● Light output is nearly double that of halogen headlamps, affording increased area of illumination. ● The light features a high relative spectral distribution at wavelengths to the human eye is most sensitive, which means that even in the rain, more light is reflected back from the road surface toward the vehicle, for added visibility. ● Power consumption is approximately 25 percent less than halogen headlamps, reducing battery load.

Provide an optimum illumination pattern designed to prevent dazzling effect on drivers of oncoming vehicles Cut-line Shade

Reflector Bulb Bulb socket Booster Provides initial voltage amplification

Battery connector (DC12V) HID control unit

Xenon

Transforms battery voltage into illumination Structure of the new xenon lamp

Conventional

Comparison of xenon headlamp and conventional halogen headlamp lighting performance (example)

HID: High Intensity Discharge

SEL440V

EL-72

HEADLAMP (without Daytime Light System) — Xenon Type — Wiring Diagram — H/LAMP — BATTERY : With gasoline engine Refer to EL-POWER.

2ND

OFF

2ND

OFF

1ST

: With diesel engine

COMBINATION SWITCH (LIGHTING SWITCH)

1ST

LOW

PASS

PASS

PASS

PASS

PASS

PASS

LOW LOW HIGH

HIGH

LOW HIGH

HIGH

LOW

LOW HIGH

HIGH

Next page

YEL133C

EL-73

HEADLAMP (without Daytime Light System) — Xenon Type — Wiring Diagram — H/LAMP — (Cont’d)

YEL004D

EL-74

HEADLAMP (without Daytime Light System) — Xenon Type — WARNING: ● The xenon headlamp has a high-tension current generating area. Be extremely careful when removing and installing. Be certain to disconnect the battery negative cable prior to removing or installing. ● When the xenon headlamp is lit, do not touch the harness (covered with red or amber insulation), bulb itself or the bulb socket with your bare hands. ● Never service a xenon headlamp with wet hands. ● When checking body side harness with a circuit tester, be certain to disconnect the harness connector from the xenon headlamp. ● When the xenon headlamp is lit, the xenon bulb must be installed in the headlamp housing. (Never turn on xenon headlamp, if the bulb is out of the headlamp housing.) CAUTION: Make sure to install the bulb securely; if the xenon bulb is improperly installed in its socket, hightension current leaks occur. This may lead to a melted bulb and/or bulb socket.

Trouble Diagnoses Symptom LH or RH xenon headlamp (low beam) blinks, lacks brightness or does not illuminate.

Possible cause

Repair order

1. Check 20A fuse [No. 30 (gasoline engine), 43 (diesel engine) : LH, No. 38 (gasoline engine), 39 (diesel engine), : RH, located in fuse and fusible link box]. Relay 2. Check Headlamp relay. Power supply circuit to headlamp 3. Verify battery positive voltage is present at terminal low beam 3 of headlamp harness with lighting switch in 쑗 “2nd” and “Low” positions. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.) Xenon bulb 4. Replace the xenon bulb with the other side bulb or new one. (If headlamps illuminate correctly, replace the bulb.) HID control unit and booster 5. Replace the HID control unit and booster as a headlamp assembly.

1. 15A fuse

2. 3.

4.

5.

1. Check 15A fuse [No. 30 (Gasoline engine), No. 43 (diesel engine), : LH, No. 38 (gasoline engine), No. 39 (diesel engine) located in fuse and fusible link box]. 2. Check continuity between headlamp harness terminal 쑗 2 and body ground. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.)

1. 15A fuse LH or RH [both headlamp high and xenon (low) beam] do not illuminate. 2. Ground circuit

LH or RH headlamp high beam does not illuminate.

1. Check bulb. 1. Bulb 2. Power supply circuit to headlamp 2. Verify battery positive voltage is present at terminal high beam 1 of headlamp harness with lighting switch in 쑗 “2nd” and “HIGH” position. (Before inspecting headlamp terminal, disconnect headlamp connector with lighting switch in “OFF” position.)

HID: High Intensity Discharge

EL-75

HEADLAMP (without Daytime Light System) — Xenon Type — Bulb Replacement CAUTION: ● After replacing a new xenon bulb, be sure to make aiming adjustments. ● Hold only the plastic base when handling the bulb. Never touch the glass envelope. ● Do not leave headlamp reflector without bulb for a long period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed. 1. Disconnect negative battery cable. 2. Remove side combination lamp and radiator grille. 3. Disconnect headlamp connector. 4. Remove headlamp assembly. WARNING: Never service a xenon headlamp with wet hands.

XENON BULB (LOW BEAM) 1. Remove headlamp seal cover.

.

2. Turn bulb socket counterclockwise with keep pushing, then remove it.

Bulb Socket

NEL765

3. Release retaining pin. 4. Remove the xenon bulb. 5. Install in the reverse order of removal. CAUTION: ● When disposing of the xenon bulb, do not break it; always dispose of it as is. ● Make sure to install the bulb securely; if the xenon bulb is improperly installed in its socket, high-tension current leaks occur. This may lead to a melted bulb and/or bulb socket.

Retaining pin

NEL551

EL-76

HEADLAMP (without Daytime Light System) — Xenon Type — Bulb Replacement (Cont’d) HIGH BEAM .

1. 2. 3. 4. 5.

Seal cover

Pull off headlamp seal cover. Disconnect bulb connector. Release retaining pin. Remove the bulb. Install in the reverse order of removal.

Retaining pin

NEL564

EL-77

COMBINATION SWITCH (LIGHTING SWITCH) OFF

1ST

IGNITION SWITCH ON or START

IGNITION SWITCH START

FUSE

2ND

Schematic

DAYTIME LIGHT CONTROL UNIT

EL-78 LOW

HIGH HEADLAMP LH

LOW

HIGH

To tail lamp

HEADLAMP RH

ALTERNATOR

HEADLAMP — Daytime Light System —

HEADLAMP RELAY RH

HEADLAMP RELAY LH

COMBINATION METER (HI BEAM INDICATOR)

CONVENTIONAL TYPE

BATTERY

YEL273C

HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — CONVENTIONAL TYPE

EL-DTRL-01

BATTERY

Refer to EL-POWER.

15A 31 : 32 :

GS

15A 32 :

GS

DI

33 :

DI

R/W

F

R

To EL-DTRL-03

R/W

R

8

5

2ND

DI

: With diesel engine

G

To EL-DTRL-03

2ND

OFF

1ST

1ST PASS

LOW

: With gasoline engine

R

R/W

OFF

GS

PASS LOW

PASS

LOW

LOW

HIGH

HIGH

HIGH

HIGH

10

9

7

6

G

R/B

P

R/G

PASS

PASS

PASS

COMBINATION SWITCH (LIGHTING SWITCH)

E111

LOW

LOW HIGH

HIGH

R/G

H

P

I

R/B

J

G

K

Next page

1 3 13 2 12 14 11 E111 9 6 5 7 8 10 W

YEL262B

EL-79

HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — (Cont’d) CONVENTIONAL TYPE

YEL005D

EL-80

HEADLAMP — Daytime Light System — Wiring Diagram — DTRL — (Cont’d) CONVENTIONAL TYPE IGNITION SWITCH ON or START

IGNITION SWITCH START

BATTERY

Refer to EL-POWER. FUSE BLOCK (J/B)

2ND

COMBINATION SWITCH (LIGHTING SWITCH)

1ST OFF

To EL-TAIL/L Preceding page

DAYTIME LIGHT CONTROL UNIT

Preceding page

To EL-DTRL-01

Preceding page

: With GA engine or diesel engine : With GA engine : With SR engine or QG engine

ALTERNATOR

ALTERNATOR

ALTERNATOR

: With diesel engine

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL137C

EL-81

OFF

1.a

FUSE

2.a

HEADLAMP RELAY LH

Schematic

HEADLAMP RELAY RH

DAYTIME LIGHT CONTROL UNIT

EL-82 COMBINATION METER (HI BEAM INDICATOR)

HEADLAMP LH LOW

HIGH

HEADLAMP RH LOW

To tail lamp

HIGH

ALTERNATOR

HEADLAMP — Daytime Light System With Xenon Type —

COMBINATION SWITCH (LIGHTING SWITCH)

IGNITION SWITCH START

XENON TYPE

IGNITION SWITCH ON or START

BATTERY

YEL274C

HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — XENON TYPE BATTERY : With gasoline engine : With diesel engine

Refer to EL-POWER.

To EL-DTRL-06

2ND

OFF

To EL-DTRL-06

2ND

OFF

1ST

COMBINATION SWITCH (LIGHTING SWITCH)

1ST PASS

LOW

PASS

LOW

PASS

LOW HIGH HIGH

LOW HIGH

HIGH

PASS

PASS

PASS LOW

LOW HIGH

HIGH

DIODE Next page

YEL138C

EL-83

HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — (Cont’d) XENON TYPE

YEL006D

EL-84

HEADLAMP — Daytime Light System With Xenon Type — Wiring Diagram — DTRL — (Cont’d) XENON TYPE IGNITION SWITCH ON or START

IGNITION SWITCH START

BATTERY

Refer to EL-POWER. FUSE BLOCK (J/B)

.

2ND

.

COMBINATION SWITCH (LIGHTING SWITCH)

1ST .

OFF

To EL-TAIL/L

DAYTIME LIGHT CONTROL UNIT

Preceding page

To EL-DTRL-04

Preceding page

: With GA engine or diesel engine : With GA engine : With SR engine or QG engine

ALTERNATOR

ALTERNATOR

ALTERNATOR

: With diesel engine

.

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL140C

EL-85

HEADLAMP — Daytime Light System — Trouble Diagnoses DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE Terminal No.

Connections

INPUT (I)/ OUTPUT (O)

Operated condition

Voltage (V) (Approximate values)

1

Power source for illumination & tail lamp

—

—

12

2

Alternator “L” terminal

I

3

Lighting switch

I

5

Power source for headlamp RH

—

6

Illumination & tail lamp

O

7

Power source for headlamp LH

—

8

Start signal

I

9

Headlamp LH (conventional type), Headlamp relay LH (xenon type)

O

10

Ground

—

11

Headlamp RH (conventional type), Headlamp relay RH (xenon type)

O

12

Power source

—

Engine

Running

12

Stopped

0

1ST⋅2ND position

12

OFF

0

—

12

ON (daytime light operating*)

12

OFF

0

—

12 START

12

ON, ACC or OFF

0

ON (daytime light operating*)

12

OFF

0

Ignition switch

—

—

ON (daytime light operating*)

12

OFF

0

Ignition switch

ON or START

12

ACC or OFF

0

*: Daytime light operating: Lighting switch in “OFF” position with engine running.

Bulb Replacement/Conventional Type For bulb replacement refer to EL-70.

Bulb specifications/Conventional Type For bulb specifications, refer to EL-137.

Aiming Adjustment/Conventional Type For aiming adjustment, refer to EL-70.

Bulb replacement/Xenon Type For bulb replacement, refer to EL-76.

Aiming Adjustment/Xenon Type For aiming adjustment, refer to EL-91.

EL-86

HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — MODELS BEFORE VIN - P11U0548750 BATTERY : With daytime light system

Refer to EL-POWER.

: Without daytime light system

Next page

2ND

OFF

COMBINATION SWITCH (LIGHTING SWITCH)

FUSE BLOCK (J/B)

1ST

Next page

DAYTIME LIGHT CONTROL UNIT

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL141C

EL-87

HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d) Preceding page

HEADLAMP AIMING SWITCH

Preceding page

HEADLAMP AIMING MOTOR RH

HEADLAMP AIMING MOTOR LH

YEL142C

EL-88

HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL834C

EL-89

HEADLAMP — Headlamp Aiming Control (Manual) — Wiring Diagram — H/AIM — (Cont’d)

YEL835C

EL-90

HEADLAMP — Headlamp Aiming Control (Auto) — System Description The auto level control unit is designed to adjust the beam angle of the headlamp in response to the loading conditions of the vehicle. It is not designed to compensate for the dynamic handling of the vehicle. The vehicle’s front and rear height is measured by sensors attached to the front stabilizer bar and the rear suspension lateral link arm. The sensors provide a signal to the auto level control unit, which calculates the correct headlamp aiming position and sends a signal to the aiming motors.

Initialisation After the replacement or adjustment of any suspension sensor, the system must be self calibrated. This is achieved as follows. The vehicle must be empty, since any load will result in an invalid calibration. From outside of the vehicle turn ignition on and then within 7 seconds the light switch must be turned from off to side lights on position, 5 times, finishing with the lamps in the on position. The headlamps will then move to the highest, then the lowest then the normal position to indicate that the calibration is successful, as can be seen by the moving beam pattern. After successful calibration the headlamps must then be aimed in the conventional manner. Refer to EL-70.

EL-91

HEADLAMP — Headlamp Aiming Control (Auto) — Component Parts and Harness Connector Location

Rear sensor

Auto level control unit

Headlamp aiming motor RH

Front sensor

Headlamp aiming motor LH

Rear sensor Headlamp aiming motor

Front sensor

Auto level control unit

NEL528

EL-92

HEADLAMP — Headlamp Aiming Control (Auto) — Wiring Diagram — H/AIM — AUTO

YEL836C

EL-93

HEADLAMP — Headlamp Aiming Control (Auto) — Wiring Diagram — H/AIM — (Cont’d)

YEL837C

EL-94

HEADLAMP — Headlamp Aiming Control (Auto) — Bulb (1.2 W or 2 W only)

Trouble Diagnosis PERFORMING SELF-DIAGNOSIS

Auto level control unit NEL530

Check headlamp aiming control (auto) system using a bulb as follows: 1. Connect a bulb 1.2W or 2W between auto level control unit 1 and 쑗 5 . connector terminal 쑗 NOTE: Do not use another bulb. This will damage the auto level control unit. Use a 1.2W or 2W bulb only. 2. After turning the ignition switch from “OFF” to “ON”, the bulb operates. 3. Compare the bulb operation to the chart below.

EL-95

HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) Lighting condition of the bulb

System condition

Reference item

No malfunction is detected. No further action is necessary.

IGN ON ON 1 sec.

—

OFF

NEL531 IGN ON ON

2 sec.

1 sec. OFF

Front sensor or front sensor circuit is malfunctioning. (When rear sensor OK)

Go to DIAGNOSTIC PROCEDURE 1 (EL-97).

Rear sensor or rear sensor circuit is malfunctioning. (Whatever the state of front sensor)

Go to DIAGNOSTIC PROCEDURE 2 (EL-97).

2 sec.

0.5 sec.

NEL532 IGN ON ON

2 sec.

1 sec. OFF

2 sec.

0.5 sec.

0.5 sec.

NEL533

Sensor supply is malfunction- Go to DIAGNOSTIC ing. PROCEDURE 1 and 2 (EL-97).

IGN ON ON

2 sec.

1 sec. OFF

2 sec.

0.5 sec.

0.5 sec.

NEL534

Aiming motor or aiming motor Go to DIAGNOSTIC circuit is malfunctioning. PROCEDURE 3 (EL-98).

IGN ON ON 1 sec. OFF

2 sec.

0.5 sec.

2 sec.

0.5 sec. NEL535

Auto level control unit is malfunctioning.

IGN ON ON

OFF

NEL536

EL-96

Replace auto level control unit.

HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) DIAGNOSTIC PROCEDURE 1 (Front sensor check) Auto leveling control unit B123

Front sensor B131

1) Disconnect control unit and front sensor connector. 2) Check harness continuity between control unit and front sensor. Continuity should exist.

NG

왘

Check harness between control unit and front sensor.

OK 왔 NEL537

1) Remove sensor. 2) Check front sensor linkage operation.

NG

왘

Replace sensor linkage.

OK 왔

Replace front sensor.

DIAGNOSTIC PROCEDURE 2 (Rear sensor check) Auto leveling control unit B123

Rear sensor B133

1) Disconnect control unit and rear sensor connector. 2) Check harness continuity between control unit and rear sensor. Continuity should exist.

NG

왘

Check harness between control unit and rear sensor.

OK 왔 NEL538

1) Remove the sensor. 2) Check rear sensor linkage operation. OK 왔

Replace rear sensor.

EL-97

NG

왘

Replace sensor linkage.

HEADLAMP — Headlamp Aiming Control (Auto) — Trouble Diagnosis (Cont’d) DIAGNOSTIC PROCEDURE 3 (Aiming motor check)

Headlamp aiming motor

Lighting switch “2nd”

CHECK POWER SUPPLY 1) Turn lighting switch to 2nd position. 2) Check voltage between aiming motor terminal 쑗 3 and ground. Battery voltage should exist.

NG

왘

Check harness between combination switch and aiming motor.

OK YEL618B

왔

CHECK GROUND CIRCUIT 1) Turn lighting switch to OFF position. 2) Check continuity between aiming motor terminal 쑗 1 and ground. Continuity should exist.

Headlamp aiming motor LH: E4 RH: E33

왘

Check harness between aiming motor and ground.

OK 왔

NEL540

1) Disconnect control unit and aiming motor connector. 2) Check harness continuity between control unit terminal 쑗 4 and aiming motor terminal 쑗 2 . Continuity should exist. OK 왔

Auto leveling control unit B123

NG

Headlamp aiming motor LH: E4

Replace aiming motor.

RH: E33

NEL541

EL-98

NG

왘

Check harness between control unit and aiming motor.

HEADLAMP — Headlamp Aiming Control (Auto) — Removal and Installation

Front sensor 4.0 - 5.0 (0.4 - 0.51, 35 - 44)

Front linkage to be clamped onto stabilizer bar with wheels down and suspension settled. Rotation to be fixed with link arm in horizontal plane.

18 mm (0.71 in) 3.3 - 7.7 (0.33 - 0.79, 29 - 68)

3.3 - 7.7 (0.33 - 0.79, 29 - 68) Rear sensor The rear sensor linkage does not require setting, but with the wheel on the ground and the suspension settled, ensure that the link arm in the same plane as the connector wire.

: N·m (kg-m, in-lb)

3.3 - 7.7 (0.33 - 0.79, 29 - 68) YEL621B

EL-99

PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L —

YEL838C

EL-100

PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) 4-DOOR MODELS

YEL839C

EL-101

PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) 5-DOOR HATCH-BACK MODELS

YEL840C

EL-102

PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) WAGON MODELS

YEL841C

EL-103

STOP LAMP Wiring Diagram — STOP —

YEL842C

EL-104

STOP LAMP Wiring Diagram — STOP — (Cont’d) 4-DOOR MODELS AND 5-DOOR HATCH-BACK MODELS

YEL843C

EL-105

STOP LAMP Wiring Diagram — STOP — (Cont’d) WAGON MODELS

YEL844C

EL-106

BACK-UP LAMP Wiring Diagram — BACK/L — IGNITION SWITCH ON or START : With CVT FUSE BLOCK (J/B)

: With M/T

Refer to EL-POWER.

: With GA engine or diesel engine : With SR engine or QG engine : Wagon models : 4 door models and 5 door hatchback models

P L

R N

D

BACK-UP LAMP SWITCH

PARK/NEUTRAL POSITION SWTICH OTHERS

Next page

To EL-BACK/L-03

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL149C

EL-107

BACK-UP LAMP Wiring Diagram — BACK/L — (Cont’d) 4-DOOR MODELS AND 5-DOOR HATCH-BACK MODELS Preceding page : LHD models : RHD models : 4 doors models : 5 door hatchback models

BACK-UP LAMP

BACK-UP LAMP

BACK-UP LAMP

BACK-UP LAMP

YEL150C

EL-108

BACK-UP LAMP Wiring Diagram — BACK/L — (Cont’d) WAGON MODELS To EL-BACK/L-01

: LHD models : RHD models

REAR COMBINATION LAMP LH (BACK-UP LAMP)

REAR COMBINATION LAMP RH (BACK-UP LAMP)

YEL270C

EL-109

FRONT FOG LAMP Wiring Diagram — F/FOG —

YEL845C

EL-110

FRONT FOG LAMP Aiming Adjustment Before performing aiming adjustment, make sure of the following. a. Keep all tires inflated to correct pressure. b. Place vehicle on level ground. c. Check that vehicle is unloaded (except for full levels of coolant, engine oil and fuel, and spare tire, jack, and tools). Have the driver or equivalent weight placed in driver’s seat. Aiming adjusting screw NEL553

1. Set the distance between the screen and the center of the fog lamp lens as shown at left. 2. Turn front fog lamps ON.

Screen Main axis of light

7.6 m (25 ft)

MEL327G

Vertical centerline ahead of left fog lamp

Top edge of high intensity zone

Vertical centerline ahead of right fog lamp

Car axis

.

100 (4)

Unit: mm (in)

3. Adjust front fog lamps so that the top edge of the high intensity zone is 100 mm (4 in) below the height of the fog lamp centers as shown at left. ● When performing adjustment, if necessary, cover the headlamps and opposite fog lamp.

Floor to center of foglamp lens (height of fog lamp centers)

.

100 (4)

High-intensity areas MEL328G

Bulb Specifications Item Front fog lamp

EL-111

Wattage (W) 55

REAR FOG LAMP Wiring Diagram — R/FOG — MODELS BEFORE VIN - P11U0548750

YEL846C

EL-112

REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) 4-door models and 5-door Hatch-back models Preceding page : LHD models : RHD models : 4 door models : 5 doors hatchback models

REAR FOG LAMP

REAR FOG LAMP

REAR FOG LAMP

REAR FOG LAMP

YEL153C

EL-113

REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL847C

EL-114

REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) 4-door models and 5-door Hatch-back models

YEL848C

EL-115

REAR FOG LAMP Wiring Diagram — R/FOG — (Cont’d) WAGON MODELS

YEL849C

EL-116

TURN SIGNAL AND HAZARD WARNING LAMPS Schematic

YEL289B

EL-117

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN —

YEL850C

EL-118

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d) MODELS BEFORE VIN - P11U0548750

YEL851C

EL-119

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d)

YEL852C

EL-120

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL854C

EL-121

TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d)

YEL855C

EL-122

TURN SIGNAL AND HAZARD WARNING LAMPS Trouble Diagnoses Symptom Turn signal and hazard warning lamps do not operate.

Possible cause 1. Hazard switch 2. Turn signal switch 3. Harness connector

E104

Turn signal lamps do not operate 1. Turn signal switch but hazard warning lamps oper2. Open in turn signal switch cirate. cuit

Repair order 1. Check hazard switch. 2. Check turn signal switch. 3. Check harness connector

E104

.

1. Check turn signal switch. 2. Check L/G and G/Y wires between time control unit and turn signal switch for open circuit. 3. Check B wire between turn signal switch and ground for open circuit.

Hazard warning lamps do not operate but turn signal lamps operate.

1. Hazard switch 2. Open in hazard switch circuit

1. Check hazard switch. 2. Check G/R wire between time control unit and hazard switch for open circuit. Check B wire between hazard switch unit and ground for open circuit.

Front turn signal lamp LH or RH does not operate.

1. Bulb 2. Grounds

1. Check bulb. 2. Check grounds

E11

and

E37

Rear turn signal lamp LH or RH does not operate.

1. Bulb 2. Grounds

1. Check bulb. 2. Check grounds T3 or B150 and B151 .

and

T4

LH and RH turn indicators do not 1. Grounds operate.

1. Check grounds

and

E37

LH or RH turn indicator does not operate.

1. Check bulb in combination meter.

1. Bulb

EL-123

E11

. or .

B48

and

D110

ILLUMINATION Schematic

YEL856C

EL-124

ILLUMINATION Wiring Diagram — ILL — MODELS BEFORE VIN - P11U0548750 BATTERY

IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

Refer to EL-POWER.

Next page

2ND 1ST OFF

COMBINATION SWITCH (LIGHTING SWITCH)

COMBINATION METER (ILLUMINATION)

HEAD LAMP WASHER SWITCH (ILLUMINATION)

DAYTIME LIGHT CONTROL UNIT

: With daytime light system : Without daytime light system

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL157C

EL-125

ILLUMINATION Wiring Diagram — ILL — (Cont’d)

YEL857C

EL-126

ILLUMINATION Wiring Diagram — ILL — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL858C

EL-127

ILLUMINATION Wiring Diagram — ILL — (Cont’d)

YEL859C

EL-128

ILLUMINATION Wiring Diagram — ILL — (Cont’d)

YEL860C

EL-129

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS System Description INTERIOR LAMP TIMER OPERATION The time control unit keeps the interior lamp illuminated for about 30 seconds when: ● the ignition key is turned from “ON” to “Acc” to “LOCK” ● the driver’s door is unlocked ● a door is opened and then closed while the ignition switch is in the “OFF” position. (Interior lamp switch in the “DOOR” position). The timer is canceled when: ● driver’s door is locked, or ● ignition switch is turned “ON”.

EL-130

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Schematic

YEL861C

EL-131

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — MODELS BEFORE VIN - P11U0548750

YEL862C

EL-132

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)

YEL865C

EL-133

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL863C

EL-134

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)

YEL866C

EL-135

INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d)

YEL864C

EL-136

BULB SPECIFICATIONS Headlamp Wattage (12 volt) High/low (without xenon headlamp) High/low (with xenon headlamp)

55/55 55/Discharge D2S type

Exterior Lamp Wattage (12 volt) Front combination lamp

Parking

5

Turn signal

21

Front fog lamp

55 (H1) Turn signal

21

Rear combination lamp Stop/Tail

21/5

Back-up

21

Side turn signal lamp

5

License plate lamp

5

High-mounted stop lamp

21

Interior Lamp Wattage (12 volt) Interior lamp

10

Map lamp

3

Step lamp

3.4

Trunk room lamp

3.4

Luggage room lamp

EL-137

5

METER AND GAUGES System Description UNIFIED CONTROL METER ● ●

● ●

Speedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled totally by control unit combined with speedometer. Digital meter is adopted for odo/trip meter.* *The record of the odometer is kept even if the battery cable is disconnected. The record of the trip meter is erased when the battery cable is disconnected. Odo/trip meter segment can be checked in diagnosis mode. Meter/gauge can be checked in diagnosis mode.

EL-138

METER AND GAUGES Combination Meter MODELS BEFORE VIN - P11U0548750

YEL229C

EL-139

METER AND GAUGES Combination Meter (Cont’d) MODELS AFTER VIN - P11U0548750

YEL956C

EL-140

METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 BATTERY

IGNITION SWITCH ON or START : With CVT FUSE BLOCK (J/B)

Refer to EL-POWER.

: With M/T : With trip computer : With outside air temperature gauge

.

ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:

COMBINATION METER

OG

VEHICLE SPEED SENSOR

ON

COMBINATION SWITCH (TRIP COMPUTER SWITCH)

OFF

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL164C

EL-141

METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 (Cont’d) .

ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:

COMBINATION METER

OG

: With CVT : With M/T : With gasoline engine : With diesel engine : With SR engine or QG engine : With trip computer : With outside air temperature gauge : With GA engine

ECM

OUTSIDE AIR TEMPERATURE SENSOR

REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS

YEL165C

EL-142

METER AND GAUGES Wiring Diagram — METER —/MODELS BEFORE VIN - P11U0548750 (Cont’d)

.

ELECTRIC SPEEDOMETER TACHOMETER WATER TEMPERATURE GAUGE FUEL GAUGE FUEL WARNING LAMP TRIP COMPUTER: TC OUTSIDE AIR TEMPERATURE GAUGE:

A/C CONTROL PANEL

COMBINATION METER

OG

HEATER ILLUMINATION

: With CVT : With M/T : With air conditioner : Without air conditioner : With GA engine : With SR engine or QG engine

FUEL LEVEL SENSOR UNIT

: With gasoline engine : With diesel engine : With trip computer : With outside air temperature gauge THERMAL TRANSMITTER

REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS

YEL166C

EL-143

METER AND GAUGES Schematic M/T MODELS AFTER VIN - P11U0548750

YEL867C

EL-144

METER AND GAUGES Schematic (Cont’d) CVT MODELS AFTER VIN - P11U0548750

YEL937C

EL-145

METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750

YEL868C

EL-146

METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750 (Cont’d)

YEL869C

EL-147

METER AND GAUGES Wiring Diagram — METER —/M/T MODELS AFTER VIN - P11U0548750 (Cont’d)

YEL870C

EL-148

METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750

YEL871C

EL-149

METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750 (Cont’d)

YEL872C

EL-150

METER AND GAUGES Wiring Diagram — METER —/CVT MODELS AFTER VIN - P11U0548750 (Cont’d)

YEL873C

EL-151

METER AND GAUGES Combination Meter Self-Diagnosis PERFORMING SELF-DIAGNOSIS MODE 1. Turn the ignition switch to the “LOCK” position. 2. Press both reset buttons on the combination meter and keep them depressed. 3. Turn the ignition switch to the “ON” position, while keeping the reset buttons pressed. 4. Release both reset buttons then self-diagnosis will start. The sequence (A to L) is activated by press the either reset buttons. NOTE: If either reset button is not pressed for 20 seconds at each step or if the ignition switch is turned OFF, the self-diagnosis mode is exited.

A)

Check items Odometer segment test

B)

Work instruction code

Display

Remarks All odo trip meter segments are ON.

This information is not used for service. Please skip this step. SEL435X

C)

This information is not used for service. Please skip this step.

Software code

NEL735

D)

This information is not used for service. Please skip this step.

EEPROM code

NEL736

E)

This information is not used for service. Please skip this step.

Hardware code

NEL737

F)

This information is not used for service. Please skip this step.

PCB code

NEL738

G)

Meter/gauge test (Sweeping movement) SEL440X

Tachometer, speedometer, fuel level gauge and water temperature gauge have sweeping movement test. (The meter/gauges operate MIN. , MAX., MAX. , MIN. for 2 times) The odo trip meter segment flashes during the sweep movement.

EL-152

METER AND GAUGES Combination Meter Self-Diagnosis (Cont’d) Check items

H)

Display

Remarks

Error 1 (Bit 0 - Bit 3) SEL441X

I)

Error E (Bit 4 - Bit 7)

The segment of each bit displays “0”, meaning no failure. If the bit(s) displays figures other than “0”, the item of the bit has failed. For details, refer to “Failure chart for Error 1 and Error E” below.

SEL442X

J)

Fuel warning lamp is on and odo trip meter segment “FUEL” flashes.

Fuel warning lamp test

SEL443X

K)

Fuel gauge calibration (CAL)

This information is not used for service. Please skip this step. SEL444X

L)

Fuel gauge calibration (OLD)

This information is not used for service. Please skip this step. SEL445X

Failure Chart for “Error 1” and “Error E” Bit

Detectable items

Description of the failure

Speedometer input signal

No input signal When no signal is detected for 30 minutes continuously with the ignition ON, it should be judged as signal failure. (If input signal is detected later, then the judgement will be canceled immediately.) Abnormal input signal When any signal of frequency which would not exist in normal conditions is detected, it should be judged as signal failure. No input signal When no signal is detected for 30 minutes continuously with the ignition ON, it should be judged as signal failure. (If input signal is detected later, then the judgement will be canceled immediately.) Abnormal input signal When any signal of frequency which would not exist in normal conditions is detected, it should be judged as signal failure.

0

Tachometer input signal

1

EL-153

Displayed figure on the bit Failure No failure

1 0 2

1 0 2

METER AND GAUGES Combination Meter Self-Diagnosis (Cont’d) Bit

2

3

4

5

6 7

Detectable items

Description of the failure

Fuel level input sig- Short circuit nal When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Water temperature Short circuit input signal When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Short circuit Outside air temperature input sig- When short circuit of the signal line is detected for 5 seconds or more, it should be judged as short-circuit failure. nal Open circuit When open circuit of the signal line is detected for 5 seconds or more, it should be judged as open-circuit failure. Right side reset button Reset buttons Short circuit for reset buttons has failed. When the short circuit is continuously detected for 5 minLeft side reset button has utes or more, it should be failed. judged as short-circuit failure. Both reset buttons have failed. — — CPU EEPROM failure CPU RAM failure

EL-154

Displayed figure on the bit Failure No failure 1 0 2

1 0 2

1 0 2

1 2

0

3 0 1 2

0 0

METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) Combination meter connector

POWER SUPPLY AND GROUND CIRCUIT CHECK Power supply circuit check Terminals 䊝

YEL489B

Ignition switch position 䊞

OFF

ACC

ON

2 쑗

Ground

Battery voltage

Battery voltage

Battery voltage

5 쑗

Ground

0V

0V

Battery voltage

If NG, check the following, ● 10A fuse [No. 16 , located in fuse block (J/B)] ● 10A fuse [No. 12 , located in fuse block (J/B)] ● Harness for open or short between fuse and combination meter

Ground circuit check Terminals 1 쑗

Combination meter connector

- Ground

YEL490B

EL-155

Continuity Yes

METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) Combination meter connector

INSPECTION/VEHICLE SPEED SENSOR CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Remove vehicle speed sensor from transmission. 2) Check voltage between combination 3 and 쑗 1 while meter terminals 쑗 quickly turning speed sensor pinion.

왘

Vehicle speed sensor is OK.

왘

Check harness for open or short between speedometer and vehicle speed sensor.

왘

Repair harness or connector

왘

Repair harness and connector.

OK

Vehicle speed sensor 왔

CHECK POWER SOURCE. ● Re-install vehicle speed sensor. ● Turn ignition switch to “ON” position. Check voltage between vehicle speed sen3 and ground. sor connector terminal 쑗 Battery voltage should exist.

This connector should remain connected.

NG

NG

OK Vehicle speed sensor pinion

왔 YEL491B

Combination meter connector

CHECK GROUND CIRCUIT OF VEHICLE SPEED SENSOR ● Turn ignition switch to the “LOCK” position. Disconnect vehicle speed sensor connector. Check continuity between vehicle speed 1 and sensor harness connector terminal 쑗 body ground. Continuity should exist.

NG

OK 왔

YEL493B

Check continuity between speedometer harness connector terminal 쑗 3 and vehicle 2 . speed sensor connector terminal 쑗 Continuity should exist. OK 왔

Replace vehicle speed sensor. Vehicle speed sensor connectors

YEL494B

Vehicle speed sensor connectors

Combination meter connector

YEL495B

EL-156

NG

METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) INSPECTION/ENGINE REVOLUTION SIGNAL Combination meter connector

YEL492B

CHECK ECM OUTPUT. 1. Start engine. 2. Check voltage between combination 1 and 쑗 11 at idle and meter terminals 쑗 2,000 rpm. Higher rpm = Higher voltage Lower rpm = Lower voltage Voltage should change with rpm. 왔

OK 왘

Engine revolution signal is OK.

NG

Check the following ● Combination meter terminal 쑗 1 ground circuit ● Harness for open or short between ECM and combination meter

INSPECTION/FUEL LEVEL SENSOR CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT. Check harness continuity between fuel level sensor unit terminal 쑗 3 and ground. Continuity should exist.

Fuel level sensor unit connector

왔 NEL764

NG

왘

Repair harness or connector.

OK

CHECK GAUGE UNITS. Refer to “FUEL LEVEL SENSOR UNIT CHECK” (EL-164).

NG

왘

Repair or replace. Refer to FE section in Service Manual.

OK Combination meter connector

Fuel level sensor unit connector

NEL763

왔

CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and fuel level sensor unit connector. 2. Check continuity between combination meter terminal 쑗 20 and fuel level sensor unit terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter 쑗 20 and ground. Continuity should exist. 왔

OK

Fuel level sensor is OK.

EL-157

NG

왘

Repair harness or connector.

METER AND GAUGES Trouble Diagnoses (Models before VIN P11U0548750) (Cont’d) INSPECTION/THERMAL TRANSMITTER Combination meter connector

Thermal transmitter connector

CHECK THERMAL TRANSMITTER. Refer to “THERMAL TRANSMITTER CHECK ” (EL-164).

NG 왘

Repair or replace.

OK 왔

YEL498B

CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and thermal transmitter connector. 2. Check continuity between combination 10 and thermal transmitmeter terminal 쑗 ter terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination 10 and ground. meter terminal 쑗 Continuity should exist. 왔

OK

Thermal transmitter is OK.

EL-158

NG 왘

Repair harness or connector.

METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) POWER SUPPLY AND GROUND CIRCUIT CHECK Power supply circuit check Terminals 䊝 YEL007D

Ignition switch position 䊞

OFF

ACC

ON

23 쑗

Ground

Battery voltage

Battery voltage

Battery voltage

쑗1

Ground

0V

0V

Battery voltage

If NG, check the following, ● 10A fuse [No. 16 , located in fuse block (J/B)] ● 10A fuse [No. 12 , located in fuse block (J/B)] ● Harness for open or short between fuse and combination meter

Ground circuit check Terminals 10 쑗

- Ground

YEL008D

EL-159

Continuity Yes

METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/VEHICLE SPEED SENSOR (MT models without ABS, and CVT models)

CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Remove vehicle speed sensor from transmission. 2) Check voltage between combination meter terminals 쑗 10 and 쑗 31 while quickly turning speed sensor pinion.

NG

왘

Vehicle speed sensor is OK.

OK 왔

YEL009D

CHECK POWER SOURCE. ● Re-install vehicle speed sensor. ● Turn ignition switch to “ON” position. Check voltage between vehicle speed sensor connector terminal 쑗 3 and ground. Battery voltage should exist.

NG

왘

Check harness for open or short between speedometer and vehicle speed sensor.

OK 왔

Combination meter connector

YEL493B

CHECK GROUND CIRCUIT OF VEHICLE SPEED SENSOR ● Turn ignition switch to the “LOCK” position. Disconnect vehicle speed sensor connector. Check continuity between vehicle speed sensor harness connector terminal 쑗 1 and body ground. Continuity should exist.

NG

왘

Repair harness or connector

왘

Repair harness and connector.

OK 왔

Check continuity between speedometer harness connector terminal 쑗 31 and vehicle speed sensor connector terminal 쑗 2 . Continuity should exist.

Vehicle speed sensor connectors

OK 왔 YEL494B

Replace vehicle speed sensor.

YEL011D

EL-160

NG

METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/VEHICLE SPEED SENSOR (MT models with ABS)

CHECK VEHICLE SPEED SENSOR OUTPUT. 1) Jack up the front wheels. 2) Turn ignition switch “ON”. 3) Check voltage between combination meter terminals 쑗 3 and 쑗 1 while turning front wheels.

NG

왘

Vehicle speed sensor is OK.

왘

Repair harness and connector.

OK 왔

Check continuity between speedometer harness connector terminal 쑗 31 and ABS actuator and electric unit connector terminal 쑗 6 . Continuity should exist. OK YEL010D

왔

Replace vehicle speed sensor.

YEL012D

EL-161

NG

METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/ENGINE REVOLUTION SIGNAL

YEL013D

CHECK ECM OUTPUT. 1. Start engine. 2. Check voltage between combination meter terminals 쑗 10 and 쑗 22 at idle and 2,000 rpm. Higher rpm = Higher voltage Lower rpm = Lower voltage Voltage should change with rpm. 왔

OK

왘

Engine revolution signal is OK.

NG

Check the following ● Combination meter terminal 쑗 1 ground circuit ● Harness for open or short between ECM and combination meter

INSPECTION/FUEL LEVEL SENSOR CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT. Check harness continuity between fuel level sensor unit terminal 쑗 3 and ground. Continuity should exist.

Fuel level sensor unit connector

왔 NEL764

NG

왘

Repair harness or connector.

OK

CHECK GAUGE UNITS. Refer to “FUEL LEVEL SENSOR UNIT CHECK”.

NG

왘

Repair or replace. Refer to FE section in Service Manual.

OK 왔

YEL014D

CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and fuel level sensor unit connector. 2. Check continuity between combination meter terminal 쑗 24 and fuel level sensor unit terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter 쑗 24 and ground. Continuity should exist. 왔

OK

Fuel level sensor is OK.

EL-162

NG

왘

Repair harness or connector.

METER AND GAUGES Trouble Diagnoses (Models after VIN P11U0548750) (Cont’d) INSPECTION/THERMAL TRANSMITTER CHECK THERMAL TRANSMITTER. Refer to “THERMAL TRANSMITTER CHECK”.

NG

왘

Repair or replace.

OK 왔 YEL015D

CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination connector and thermal transmitter connector. 2. Check continuity between combination meter terminal 쑗 20 and thermal transmitter terminal 쑗 1 . Continuity should exist. 3. Check continuity between combination meter terminal 쑗 20 and ground. Continuity should exist. 왔

OK

Thermal transmitter is OK.

EL-163

NG

왘

Repair harness or connector.

METER AND GAUGES Fuel Level Sensor Unit Check G

E *3

● For removal, refer to FE section (“FUEL SYSTEM”). Check the resistance between terminals (G) and (E).

QG & SR Engine Models Resistance value (Ω)

Ohmmeter Float position mm (in)

*2

(+)

(−)

*1

*3 NEL330

E

G

E

Full

151 (5.945)

7.5 - 9.5

*2

1/2

88 (3.465)

88.5 - 93.5

*1

Empty

15 (0.591)

180.0 - 186.8

*1 and *3: When float rod is in contact with stopper.

G

CD20T Engine Models *1

Resistance value (Ω)

Ohmmeter

*2

Float position mm (in) *3

(+)

(−)

G

E

NEL329

*3

Full

18 (0.709)

7.5 - 9.5

*2

1/2

84 (3.307)

88.5 - 93.5

*1

Empty

158 (6.220)

180.0 - 186.8

*1 and *3: When float rod is in contact with stopper.

Thermal Transmitter Check Check the resistance between the terminals of thermal transmitter and body ground. Ohmmeter

Water temperature °C (°F)

Resistance (Ω)

65 (149)

Approx. 951 - 1109

91 (196)

Approx. 433 - 510

SEL233P

EL-164

: CVT models : H⋅CVT models IGNITION SWITCH ON or START

: H⋅CVT (M6) models : With GA engine : With SR engine or QG engine

FUSE

: With diesel engine

REAR FRONT DOOR DOOR SWITCH SWITCH (PASSEN- LH GER SIDE)

REAR WASHER BRAKE PARKING VACUUM SEDIMENTER ABS SWITCH SENSOR ACTUATOR DOOR LEVEL FLUID BRAKE AND ELECSWITCH SWITCH LEVEL SWITCH TRIC UNIT RH SWITCH (CONTROL UNIT)

ECM

TCM (TRANSMISSION CONTROL MODULE)

WARNING LAMPS

TRUNK ROOM LAMP SWITCH OR LUGGAGE ROOM LAMP SWITCH

Warning Lamps/Schematic

FUEL OIL PRES- ALTER- FRONT LEVEL SURE NATOR DOOR SENSOR SWITCH SWITCH UNIT (DRIVER SIDE)

GLOW

Electronic speedometer module

DIAGNOSIS SENSOR UNIT

MALFUNCTION INDICATOR LAMP

ABS

BRAKE

WASH

DOOR

CHARGE

OIL

FUEL

COMBINATION METER

EL-165

TIME CONTROL UNIT

CVT WARNING LAMP SPORT INDICATOR LAMP

AIR BAG

MODELS BEFORE VIN - P11U0548750

: M/T models

YEL167C

WARNING LAMPS Warning Lamps/Schematic (Cont’d) MODELS AFTER VIN - P11U0548750

YEL874C

EL-166

WARNING LAMPS Wiring Diagram — WARN — MODELS BEFORE VIN - P11U0548750 IGNITION SWITCH ON or START FUSE BLOCK (J/B)

: CVT models Refer to EL-POWER. : M/T models

Next page

To EL-WARN-06

FUEL

COMBINATION METER

OIL

AIR BAG ELECTRONIC SPEEDOMETER MODULE

FUSE BLOCK (J/B)

FUEL LEVEL SENSOR UNIT

DIAGNOSIS SENSOR UNIT

OIL PRESSURE SWITCH HIGH LOW

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL168C

EL-167

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

EL-WARN-02 C CV Preceding page

A

C CVT WARNING LAMP

CHARGE

14

Y/R

OR/B

GA : With GA engine

E124 CV

: H⋅CVT models

MC : H⋅CVT (M6) models

COMBINATION METER

MC

SPORT INDICATOR LAMP

22

Next page

: CVT models

SQ : With SR engine or QG engine

M38

DI

: With diesel engine

GA SQ

DI

Y/R 8

Y/R E42

6

F4

Y/R

Y/R

E43 F2

Y/R

Y/R

Y/R

1 L

1 L ALTERNATOR

F6

:

OR/B 13 L ALTERNATOR

F6

SQ

:

DI

ALTERNATOR

E72 :

TCM (TRANSMISSION CONTROL MODULE)

GA M48 :

1 2 3 4 5 6 7 8

1 2

F6 GY

F2 GY

33 34 35 36 37 38 39 40 E124 21 22 23 24 25 26 27 28 29 30 31 32 W

1 2 3 4 5 6 7 8 9 10

F4 GY

C

13 14 15 16 17 18 19 20 M38 1 2 3 4 5 6 7 8 9 10 11 12 GY

9 2 7 6 5 4 3 8 1 M48 18 17 16 15 14 13 12 11 10 W 24 23 22 21 20 19

YEL307B

EL-168

WARNING LAMPS Wiring Diagram — WARN — (Cont’d) Preceding page

To EL-WARN-05

COMBINATION METER

DOOR

Next page

TIME CONTROL UNIT

FUSE BLOCK (J/B)

OPEN

FRONT DOOR SWITCH (PASSENGER SIDE)

OPEN

CLOSED

OPEN

REAR DOOR SWITCH RH

CLOSED

FRONT DOOR SWITCH (DRIVER SIDE)

OPEN

CLOSED

REAR DOOR SWITCH LH

CLOSED

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

*:

This connector is not shown in “HARNESS LAYOUT” of el section.

YEL169C

EL-169

WARNING LAMPS Wiring Diagram — WARN — (Cont’d) Preceding page

: 4 door models : 5 door hatchback models : Wagon models : 5 door hatchback models and Wagon models

OPEN

TRUNK ROOM LAMP SWITCH

OPEN

CLOSED

LUGGAGE ROOM LAMP SWITCH

CLOSED

YEL170C

EL-170

WARNING LAMPS Wiring Diagram — WARN — (Cont’d) To EL-WARN-03

Next page WASH

LOW HIGH

WASHER LEVEL SWITCH

LOW

: With diesel engine

COMBINATION METER

BRAKE

BRAKE FLUID LEVEL SWITCH

HIGH

LOW HIGH

VACUUM SWITCH

APPLIED

PARKING BRAKE SWITCH

RELEASED

YEL171C

EL-171

WARNING LAMPS Wiring Diagram — WARN — (Cont’d) To EL-WARN-01 Preceding page

MALFUNCTION INDICATOR LAMP

ABS

GLOW

COMBINATION METER

: CVT models : M/T models : With gasoline engine : With diesel engine : With GA engine : With SR engine or QG engine

HIGH

SEDIMENTER SENSOR

LOW

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

ECM

REFER TO THE FOLLOWING ELECTRICAL UNITS ELECTRICAL UNITS

YEL172C

EL-172

WARNING LAMPS Wiring Diagram — WARN — (Cont’d) MODELS AFTER VIN - P11U0548750

YEL875C

EL-173

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

YEL876C

EL-174

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

YEL877C

EL-175

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

YEL878C

EL-176

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

YEL879C

EL-177

WARNING LAMPS Wiring Diagram — WARN — (Cont’d)

YEL880C

EL-178

WARNING LAMPS Electrical Components Inspection FUEL WARNING LAMP OPERATION CHECK Fuel level sensor unit connector

172 - 180Ω resistor

1. Turn ignition switch “OFF”. 2. Disconnect fuel level sensor unit harness connector B31 . 3. Connect a resistor (172 - 180Ω) between fuel tank gauge unit 1 and 쑗 3 . harness connector terminals 쑗 4. Turn ignition switch “ON”. The fuel warning lamp should come on.

YEL455B

OIL PRESSURE SWITCH CHECK Ohmmeter

MEL425F

Oil pressure kPa (kg/cm2, psi)

Continuity

Engine start

More than 10 - 20 (0.1 - 0.2, 1 - 3)

NO

Engine stop

Less than 10 - 20 (0.1 - 0.2, 1 - 3)

YES

Check the continuity between the terminals of oil pressure switch and body ground.

EL-179

WARNING CHIME System Description The warning chime is combined with the time control unit. The light warning chime will not sound, when ignition switch in the ON or START position. (When power supply exists at time control unit terminal 쑗 1 .)

LIGHT WARNING CHIME With ignition switch in the OFF position, driver’s door open, and lighting switch in 1ST or 2ND position, warning chime will sound. A battery positive voltage is supplied ● from lighting switch terminal 쑗 12 or daytime light control unit terminal 쑗 6 ● to time control unit terminal 쑗 10 . Ground is supplied ● through driver side door switch ● to time control unit terminal 쑗 6 .

EL-180

WARNING CHIME Wiring Diagram — CHIME —

YEL348D

EL-181

WARNING CHIME Wiring Diagram — CHIME — (Cont’d)

YEL881C

EL-182

WARNING CHIME Trouble Diagnoses EL-184

EL-184

EL-185

DIAGNOSTIC PROCEDURE 3

DIAGNOSTIC PROCEDURE 1 (Lighting switch input signal check)

EL-183

POWER SUPPLY AND GROUND CIRCUIT CHECK

REFERENCE PAGE

DIAGNOSTIC PROCEDURE 2 (Key switch input signal check)

SYMPTOM CHART

Light warning chime does not activate.

X

X

Ignition key warning chime does not activate.

X

All warning chimes do not activate.

X

SYMPTOM

X X

X X

POWER SUPPLY AND GROUND CIRCUIT CHECK Power Supply Circuit Check Time control unit connector

Terminals

䊝

Ignition switch position 䊞

OFF

ACC

ON

9 쑗

Ground

Battery voltage

Battery voltage

Battery voltage

1 쑗

Ground

0V

0V

Battery voltage

YEL430B

Ground Circuit Check Time control unit connector

Terminals 16 쑗

- Ground

YEL431B

EL-183

Continuity Yes

WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Lighting switch input signal check) Time control unit connector

CHECK LIGHTING SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 10 and ground. YEL432B

Condition of lighting switch

Voltage [V]

1ST or 2ND

Approx. 12

OFF

0

NG

왘

Check the following. 15A fuse (No. 34 , located in the fuse and fusible link box) ● Harness for open or short between control unit and lighting switch ●

OK 왔

Go to Procedure 3.

DIAGNOSTIC PROCEDURE 2 (Key switch input signal check)

Time control unit connector : Approx. 12V : 0V

CHECK KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch

Voltage [V]

Key is inserted.

Approx. 12

Key is withdrawn.

0

YEL433B

OK

왔

Go to Procedure 3.

EL-184

NG

왘

Check the following. Key switch Refer to “Electrical Components Inspection” (EL-185). ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse ● Harness for open or short between control unit and key switch ●

WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) terminal 16J and ground.

Fuse block (J/B) connector

YEL434B

Condition of driver’s door

Voltage [V]

Driver side door is closed.

Approx. 12

Driver side door is open.

NG

왘

0

OK 왔 Time control unit connector

Fuse block (J/B) connector

Check continuity between fuse block (J/B) terminal 16J and control unit terminal 쑗 6 . Continuity should exist.

NG

왘

Check the following. ● Driver side door switch Refer to “Electrical Components Inspection” (EL-185). ● Door switch ground circuit ● Harness for open or short between control unit and door switch

Replace fuse block (J/B).

OK 왔

Replace time control unit. YEL435B

Electrical Components Inspection KEY SWITCH (insert) Key switch connector

Check continuity between terminals when key is inserted in ignition key cylinder and key is removed from ignition key cylinder. Terminal No. 1 - 쑗 2 쑗

Condition

Continuity

Key is inserted.

Yes

Key is removed.

No

YEL436B

DRIVER SIDE DOOR SWITCH Check continuity between terminals when door switch is pushed and released. Terminal No. 2 - 쑗 3 (Type-1) or 쑗 1 - Ground (Type-2) 쑗

YEL026D

YEL025D

EL-185

Condition

Continuity

Door switch is pushed.

No

Door switch is released.

Yes

FRONT WIPER AND WASHER System Description WIPER OPERATION The wiper switch is controlled by a lever built into the combination switch. There are three wiper switch positions: ● LO speed ● HI speed ● INT (Intermittent). With the ignition switch in the ON or START position, power is supplied ● through 20A fuse (No. located in the fuse block) ● to wiper motor terminal 쑗 6 and 쑗 3 .

Low and high speed wiper operation Ground is supplied to wiper switch terminal 쑗 17 through body grounds E11 and When the wiper switch is placed in the LO position, ground is supplied ● Through terminal 쑗 14 of the wiper switch ● to wiper motor terminal 쑗 2 . With power and ground supplied, the wiper motor operates at low speed. When the wiper switch is placed in the HI position, ground is supplied ● Through terminal 쑗 16 of the wiper switch ● to wiper motor terminal 쑗 1 . With power and ground supplied, the wiper motor operates at high speed.

E37

.

Auto stop operation With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield base. When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided ● from terminal 쑗 14 of the wiper switch ● to wiper motor terminal 쑗 2 , in order to continue wiper motor operation at low speed. Ground is also supplied ● through terminal 쑗 13 of the wiper switch ● to front wiper relay terminal 쑗 3 ● through terminal 쑗 4 of the front wiper relay ● to wiper motor terminal 쑗 5 ● through terminal 쑗 4 of the wiper motor, and ● through body grounds E11 and E37 . When wiper arms reach base of windshield, wiper motor terminals 쑗 5 and 쑗 3 are connected instead of terminals 쑗 5 and 쑗 4 . Wiper motor will then stop wiper arms at the PARK position.

Intermittent operation With variable intermittent The wiper motor operates the wiper arms at a set interval of approximately 2 to 20 seconds. This feature is controlled by the combination switch wiper amplifier. When the wiper switch is placed in the INT position, ground is supplied ● to front wiper relay terminal 쑗 5 ● from wiper switch terminal 쑗 13 ● through body grounds E37 and E11 . ● to wiper motor terminal 쑗 2 ● through the wiper switch terminal 쑗 14 ● to wiper switch terminal 쑗 13 ● through front wiper relay terminal 쑗 3 The desired interval time is input ● to front wiper relay terminal 쑗 1 ● from wiper switch terminal 쑗 20 . The wiper motor operates at low speed at the desired time interval.

EL-186

FRONT WIPER AND WASHER System Description (Cont’d) WIPER OPERATION Without variable intermittent The wiper motor operates the wiper arms at an interval of approximately 7 seconds. This feature is controlled by the combination switch wiper amplifier. When the wiper switch is placed in the INT position, ground is supplied ● to front wiper relay terminal 쑗 5 ● from wiper switch terminal 쑗 13 ● to wiper motor terminal 쑗 2 ● through the wiper switch terminal 쑗 14 ● to wiper switch terminal 쑗 13 ● through front wiper relay terminal 쑗 3

WASHER OPERATION With the ignition switch in the ON or START position, power is supplied ● through 10A fuse (No. 21 , located in the fuse block) ● to washer switch terminal 쑗 5 . When the lever is pulled to the WASH/F position, ground is supplied ● to washer motor terminal 쑗 2 ● from terminal 쑗 18 of the wiper switch ● through terminal 쑗 4 of the wiper switch, and ● through body grounds E37 and E11 . Power is supplied ● from terminal 쑗 3 of the washer switch ● to washer motor terminal 쑗 1 . With power and ground supplied, the washer motor operates. When the lever is pulled to the WASH position for one second or more, the wiper motor operates at low speed for approximately 3 seconds to clean windshield. This feature is controlled by the combination switch (wiper amplifier) in the same manner as the intermittent operation.

EL-187

FRONT WIPER AND WASHER Wiring Diagram — WIPER — IGNITION SWITCH ON or START

FUSE BLOCK (J/B)

: LHD models

Refer to EL-POWER.

: RHD models

Next page

OFF MIST

Next page

HI

OFF

INT LO

OFF

COMBINATION SWITCH (FRONT WIPER SWITCH)

HI INT LO Next page

LOW

HIGH

FRONT WIPER MOTOR Next page

Next page

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL175C

EL-188

FRONT WIPER AND WASHER Wiring Diagram — WIPER — (Cont’d)

YEL882C

EL-189

FRONT WIPER AND WASHER Removal and Installation WIPER ARMS Clearance “C” (Passenger side)

Clearance “C” (Driver side)

Cowl top seal NEL310

1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). 2. Lift the blade up and then set it down onto glass surface. Set the blade center to clearance “C” immediately before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it “OFF”. 4. Ensure that wiper blades stop within clearance “C”. Clearance “C”: 19 - 33 mm (0.75 - 1.30 in) ● Tighten windshield wiper arm nuts to specified torque. : 21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-lb)

●

Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

EL-190

FRONT WIPER AND WASHER Removal and Installation (Cont’d) WIPER LINKAGE LHD models* 3.8 - 5.1 (0.39 - 0.52, 33.9 - 45.1)

3.8 - 5.1 (0.39 - 0.52, 33.9 - 45.1)

: N·m (kg-m, in-lb) MEL664DA

* Structure is basically the opposite for RHD models.

Removal 1. 2. 3. Be

Remove 4 bolts that secure wiper motor. Detach wiper motor from wiper linkage at ball joint. Remove wiper linkage. careful not to break ball joint rubber boot.

Installation ● Grease ball joint area before installation. 1. Installation is the reverse order of removal.

EL-191

FRONT WIPER AND WASHER Front Washer Nozzle Adjustment

Suitable tool

●

Max. 10°

Nozzle hole bore diameter 0.8 mm (0.031 in)

Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction)

GEL013

Unit: mm (in)

Front washer RHD models

*1

375 (14.76)

*5

115 (4.53)

*2

160 (6.30)

*6

190 (7.48)

*3

440 (17.32)

*7

320 (12.60)

*4

100 (3.94)

*8

450 (17.72)

Circle diameters are approx. 80 mm (3.15 in). Black printed edge

LHD models

Black printed edge NEL311

Front Washer Tube Layout Front washer tube Front washer nozzle

To rear washer

Washer tank NEL312

EL-192

REAR WIPER AND WASHER System Description WIPER OPERATION The rear wiper switch and rear intermittent wiper control is built into the combination switch. There are two rear wiper switch positions: ● ON (LO speed) ● INT (Intermittent). With the ignition switch in the ON or START position, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper motor terminal 쑗 3 (Sedan and H/B); 쑗 4 (Wagon), and ● to rear wiper relay terminal 쑗 2 .

Low speed wiper operation Ground is supplied to rear wiper switch terminal 쑗 4 through body grounds E37 and When the rear wiper is placed in the ON position, ground is supplied ● through rear wiper switch terminal 쑗 2 ● to rear wiper relay terminal 쑗 1 . The rear wiper relay is energized and power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 5 ● through rear wiper relay terminal 쑗 3 ● to rear wiper motor terminal 쑗 2 . Ground is supplied ● to rear wiper motor terminal 쑗 1 (sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon).

E11

.

Auto stop operation With the rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear window base. When wiper arm is not located at base of rear window with rear wiper switch OFF, rear wiper relay is not energized. Power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper motor terminal 쑗 3 (Sedan and H/B); 쑗 4 (Wagon). Ground is also supplied ● to rear wiper motor terminal 쑗 1 (Sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon). When wiper arm reaches base of rear window, rear wiper motor will then stop wiper arm at the PARK position.

Intermittent operation The rear wiper motor operates the wiper arm one time at low speed at an interval of approximately 7 seconds. This feature is controlled by the rear wiper amplifier. With the ignition switch in the ON or START position, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 2 . When the rear wiper is placed in the INT position, ground is supplied ● to rear wiper relay terminal 쑗 1 ● through rear wiper switch terminal 쑗 2 ● to rear wiper amplifier ● from rear wiper switch terminal 쑗 4 ● through bogy grounds E37 and E11 . When the rear wiper relay is energized, power is supplied ● through 15A fuse (No. 18 , located in the fuse block) ● to rear wiper relay terminal 쑗 5 ● through rear wiper relay terminal 쑗 3 ● to rear wiper motor terminal 쑗 2 .

EL-193

REAR WIPER AND WASHER System Description (Cont’d) Ground is also supplied ● to rear wiper motor terminal 쑗 1 (Sedan and H/B); 쑗 3 (Wagon) ● through body grounds B18 and B27 (Sedan); D110 and B48 (H/B and Wagon). With power and ground supplied, the rear wiper motor operates intermittently.

WASHER OPERATION With the ignition switch in the ON or START position, power is supplied ● through 10A fuse (No. 21 , located in the fuse block) ● to rear washer switch connector terminal 쑗 5 . When the rear washer switch is pushed to the WASH/R position, ground is supplied ● to rear washer motor terminal 쑗 1 ● from terminal 쑗 3 of rear wiper switch ● through terminal 쑗 4 of rear wiper switch, and ● through body grounds E37 and E11 . Power is supplied ● from terminal 쑗 18 of the washer switch ● to washer motor terminal 쑗 2 . With power and ground is supplied, the rear washer motor operates. The rear wiper motor operates when the control switch is pushed to WASH position for one second or more and for approximately 3 seconds after the switch is released. This feature is controlled by the rear wiper amplifier in the same manner as the intermittent operation.

EL-194

REAR WIPER AND WASHER Wiring Diagram — WIP/R —

YEL883C

EL-195

REAR WIPER AND WASHER Wiring Diagram — WIP/R — (Cont’d) : 4 door models Preceding page

: 5 door hatch-back models : Wagon models : 5 door hatchback models and Wagon models

STOP

STOP

MOVE REAR WIPER MOTOR

MOVE REAR WIPER MOTOR

YEL178C

EL-196

REAR WIPER AND WASHER Removal and Installation

Sedan 60 (2.4)

WIPER ARM 1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it off (Auto Stop). 2. Lift the blade up and then set it down onto glass surface. Set the blade center before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it off. 4. Ensure that wiper blade stops in the correct position. ● Tighten windshield wiper arm nut to specified torque. : 13 - 18 N·m (1.4 - 1.8 kg-m, 10 - 13 ft-lb)

Molding edge

Hatchback

170.3 (6.7)

Back door side

Wagon

66 (2.6) Unit: mm (in)

YEL456B

●

Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

Suitable tool

Washer Nozzle Adjustment ●

Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction)

Max. 10°

Nozzle hole bore diameter 1.0 mm (0.039 in)

NEL314

EL-197

REAR WIPER AND WASHER Washer Nozzle Adjustment (Cont’d) *3

*1

*4

Unit: mm (in)

*2

*1

150 (5.91)

*3

135 (5.31)

*2

290 (11.42)

*4

170 (6.69)

Circle diameters are approx. 80 mm (3.15 in)

Black printed edge All these diameters of these circles Unit: mm (in) NEL315 are less than 80 (3.15)

EL-198

REAR WIPER AND WASHER Washer Tube Layout Sedan and Hatchback

Nozzle Check valve Wagon

Rear washer tube To reservoir tank

Rear washer tube

Check valve Nozzle (Sedan)

Nozzle Check valve

● Check valve

To nozzle

A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction.

SEL411H

Hatchback and wagon

From reservoir tank

NEL557

Check Valve

Sedan

From reservoir tank

To reservoir tank

Check valve

To nozzle

NEL552

EL-199

HEADLAMP WASHER Wiring Diagram — HLC —

EL-HLC-01

IGNITION SWITCH ON or START

BATTERY

30A d

10A 12

FUSE BLOCK (J/B)

HD

: With XENON headlamp or daytime light system

XH

: Except

Refer to EL-POWER.

HD

E104 LG/B

13G G

XH LG/B

G

P/L

5

4

2

P/L

A Next page

HD P/L

B

HEADLAMP WASHER TIMER

E126 3

1

OR/B

R/B

OR/B

R/B 2

2

M

HEADLAMP WASHER MOTOR

ON

E38

HEADLAMP WASHER SWITCH

E128 OFF

1

3

B

B

B

B

E11

E37 REFER TO THE FOLLOWING

3 2 4 1 5

E104 E126 B

1 2

E38

1 6 4 3 2 5

FUSE BLOCK - Junction Box (J/B)

E128 L

YEL319B

EL-200

HEADLAMP WASHER Wiring Diagram — HLC — (Cont’d) BATTERY

Refer to EL-POWER. : With gasoline engine : With diesel engine : With XENON headlamp or daytime light system : Except : With daytime light system and without XENON headlamp : With daytime light system and XENON headlamp : With XENON headlamp and without daytime light system.

1ST

OFF

2ND

OFF

1ST

2ND COMBINATION SWITCH (LIGHTING SWITCH)

PASS

LOW HIGH

Preceding page

HEADLAMP RELAY RH

HEADLAMP RELAY RH

DIODE

HEADLAMP RELAY RH

Preceding page To Headlamp RH (Refer to EL-H/LAMP and EL-DTRL)

YEL179C

EL-201

HEADLAMP WASHER Washer Tube Layout Washer nozzle

To reservoir tank

Check valve NEL555

Check Valve

Check valve From reservoir tank

To nozzle

●

A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction.

To nozzle

NEL554

EL-202

HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — Type-1 BATTERY : With gasoline engine

Refer to EL-POWER.

: With diesel engine : With steering wheel switch : Without steering wheel switch

HORN RELAY

FUSE BLOCK (J/B)

SPIRAL CABLE

HORN LOW

ON

HORN HIGH OFF

HORN SWITCH

ON

HORN SWITCH

OFF

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

*:

This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL180C

EL-203

HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d) IGNITION SWITCH ACC or ON

BATTERY

IGNITION SWITCH ON or START

BATTERY FUSE BLOCK (J/B)

Refer to EL-POWER.

: With gasoline engine : With diesel engine : With XENON headlamp, gasoline engine : Except

POWER FUSE 15A

COMBINATION METER (CLOCK) CLOCK

CIGARETTE LIGHTER SOCKET

ST

OFF ON ACC

IGNITION SWITCH

ACC

POWER SOCKET ACCESSORY RELAY

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL181C

EL-204

HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d) Type-2

YEL885C

EL-205

HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram — HORN — (Cont’d)

YEL886C

EL-206

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER System Description The rear window and door mirror defogger system is controlled by the time control unit. The rear window and door mirror defogger operates only for approximately 15 minutes. Power is supplied at all times ● to rear window defogger relay With the ignition switch in the ON or START position, power is supplied ● to rear window defogger relay ● to time control unit terminal 쑗 1 ● through 10A fuse [No. 26 , located in the fuse block (J/B)]. Ground is supplied to terminal 쑗 14 of the rear window defogger switch through body grounds M6 , M28 and M26 . When the rear window defogger switch is turned ON, ground is supplied ● through terminal 쑗 16 rear window defogger switch ● to fuse block (J/B) terminal 9C . ● through time control unit terminal 쑗 3 . Terminal 쑗 13 of the time control unit then supplies ground to the rear window defogger relay. With power and ground supplied, the rear window defogger relay is energized. For rear window defogger system, power is supplied ● through 15A fuse [No. 14 and 15 , located in the fuse block (J/B)]. ● to rear window defogger. For door mirror defogger system, power is supplied ● through 10A fuse [No. 1 , located in the fuse block (J/B)]. ● to door mirror defogger. The rear window and door mirror defogger have an independent ground. With power and ground supplied, the rear window and door mirror filaments heat and defog the rear window and door mirrors. When the system is activated, the rear defogger indicator illuminates in the rear window defogger switch. Power is supplied ● to terminal 쑗 13 of the rear window defogger switch ● from 10A fuse [No. 1 , located in the fuse block (J/B)]. M6 , M28 and M26 . 14 of the rear window defogger switch is grounded through body grounds Terminal 쑗

EL-207

IGNITION SWITCH ON or START

BATTERY : With door mirror heater

REAR WINDOW DEFOGGER RELAY

REAR WINDOW DEFOGGER SWITCH FUSE

Schematic

EL-208 DOOR MIRROR HEATER (PASSENGER SIDE)

DOOR MIRROR HEATER (DRIVER’S SIDE)

TIME CONTROL UNIT

REAR WINDOW DEFOGGER

CONDENSER

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER

FUSE

FUSE

YEL182C

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — BATTERY

IGNITION SWITCH ON or START

BATTERY

REAR WINDOW DEFOGGER RELAY

TIME CONTROL UNIT

FUSE BLOCK (J/B)

Refer to EL-POWER.

: With door mirror heater : 4 door models and 5 door hatchback models : Wagon models

To EL-DEF-03

ON

INDICATOR LAMP

REAR WINDOW DEFOGGER SWITCH

Next page

OFF

REAR WINDOW DEFOGGER

REAR WINDOW DEFOGGER CONDENSER

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL183C

EL-209

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — (Cont’d)

EL-DEF-02 Preceding page

A

L/R

4D

: 4 door models

5H

: 5 door hatchback models

5H 4D

L/R

L/R B44 1

D103

L/R

3 L/R

R/W D113 :

5H

3 REAR WINDOW DEFOGGER

1 B41 :

5H

B B

B59 -3 :

4D

3 REAR WINDOW DEFOGGER

L/R

B

1

2

1 B120 B

B44 L/R

R/W

1

2

CONDENSER

D111 , D115 :

4D

*

*

D111 B

1

B59 -1 B

D115 B

2

2

*

3

B59 -2 B

D103 2

B

CONDENSER

B59 -1 , B59 -2 :

1

B

D113 B

3

1

*

B59 -3 B

B119

B41 B

1 2 3

5H

B

B

B48

D110

B44 W

*

1 B120 B

: These connectors are not shown in “HARNESS LAYOUT” of EL section.

YEL343B

EL-210

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Wiring Diagram — DEF — (Cont’d)

YEL887C

EL-211

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Trouble Diagnoses DIAGNOSTIC PROCEDURE SYMPTOM: Rear window defogger/door mirror defogger does not activate, or does not go off after activating.

Time control unit connector

YEL438B

Time control unit connector

CHECK REAR WINDOW DEFOGGER INPUT SIGNAL. 1. Remove control unit from fuse block (J/B). 2. Check continuity between control unit 3 and ground. harness terminal 쑗 Condition

Continuity

Rear window defogger switch is “OFF”.

No

Rear window defogger switch is “ON”.

Yes

NG 왘

Check the following. ● Rear window defogger switch ● Harness for open or short between control unit and rear window defogger switch ● Rear window defogger switch ground circuit

OK 왔 YEL439B

1. Turn ignition switch to ON position. 2. Check voltage between control unit termi1 and ground. nal 쑗 Battery voltage should exist.

NG 왘

Check the following. ● 10A fuse [No. 26 , located in the fuse block (J/B)]

OK 왔 Time control unit connector

1. Turn ignition switch to ON position. 2. Check voltage between control unit termi13 and ground. nal 쑗 Battery voltage should exist.

NG 왘

Check the following. ● Rear window defogger relay

OK 왔 YEL440B

Fuse block (J/B) connector

CHECK REAR WINDOW DEFOGGER OUTPUT SIGNAL. 1. Install control unit to fuse block (J/B). 2. Turn ignition switch to ON POSITION. 3. Check voltage between fuse block (J/B) harness terminal 1K and ground. Condition

Voltage [V]

Rear window defogger switch is “OFF”.

0

Rear window defogger switch is “ON”.

Approx. 12

OK 왘

Check the following. ● Rear window defogger filament (Refer to EL-213.)

NG YEL441B

Super multiple junction (SMJ) connector

왔

CHECK CONTROL UNIT GROUND CIRCUIT. Check continuity between fuse block (J/B) terminal 1B and ground. Continuity should exist. OK

NG 왘

Check the following. ● 15A fuse [No. 14 , 15 , located in the fuse block (J/B)] ● Rear window defogger relay OK

왔

왔

Replace relay or fuse.

Repair harness or connectors. 왔

Replace control unit. YEL442B

EL-212

NG

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Electrical Components Inspection REAR WINDOW DEFOGGER RELAY Check continuity between terminals

3 쑗

and

Condition

5 . 쑗

Continuity

12V direct current supply between 1 and 쑗 2 terminals 쑗

Yes

No current supply

No

YEL443B

REAR WINDOW DEFOGGER SWITCH Check continuity between terminals when rear window defogger switch is pushed and released.

Rear window defogger switch

Terminals

16 - 쑗 14 쑗

Condition

Continuity

Rear window defogger switch is pushed

Yes

Rear window defogger switch is released

No

YEL444B

Filament Check 1. Attach probe circuit tester (in volt range) to middle portion of each filament.

6 volts (normal filament) SEL263

● Heat wire

Press

When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger.

Tester probe

Tin foil

SEL122R

EL-213

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Filament Check (Cont’d) 2. If a filament is burned out, circuit tester registers 0 or 12 volts.

Burned out point

12 volts

Burned out point

0 volts SEL265

3. To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the point.

SEL266

Filament Repair REPAIR EQUIPMENT

Heat wire

REPAIRING PROCEDURE

5 (0.20)

5 (0.20)

1. Conductive silver composition (Dupont No. 4817 or equivalent) 2. Ruler 30 cm (11.8 in) long 3. Drawing pen 4. Heat gun 5. Alcohol 6. Cloth

Break

Ruler

Drawing pen

Unit: mm (in) BE540

1. Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break.

EL-214

REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER Filament Repair (Cont’d) 4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is being conducted.

Repaired point

SEL012D

5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet. If a heat gun is not available, let the repaired area dry for 24 hours.

Repaired point

Heat gun SEL013D

EL-215

AUDIO Anti-theft System NATS Audio Link Description The link with the NATS IMMU implies that the audio unit can basically only be operated if connected to the matching NATS IMMU to which the audio unit was initially fitted on the production line. Since radio operation is impossible after the link with the NATS is disrupted theft of the audio unit is basically useless since special equipment is required to reset the audio unit. Initialization process for audio units that are linked to the NATS IMMU New audio units will be delivered to the factories in the “NEW” state, i.e. ready to be linked with the vehicle’s NATS. When the audio unit in “NEW” state is first switched on at the factory, it will start up communication with the vehicle’s immobiliser control unit (IMMU) and send a code (the “audio unit Code”) to the IMMU. The IMMU will then store this code, which is unique to each audio unit, in its (permanent) memory. Upon receipt of the code by the IMMU, the NATS will confirm correct receipt of the audio unit code to the audio unit. Hereafter, the audio unit will operate as normal. During the initialisation process, “NEW” is displayed on the audio unit display. Normally though, communication between audio unit and IMMU takes such a short time (300 ms) that the audio unit seems to switch on directly without showing “NEW” on its display. Normal operation Each time the audio unit is switched on afterwards, the audio unit code will be verified between the audio unit and the NATS before the audio unit becomes operational. During the code verification process, “WAIT” is shown on the audio unit display. Again, the communication takes such a short time (300 ms) that the audio unit seems to switch on directly without showing “WAIT” on its display. When the radio is locked In case of a audio unit being linked with the vehicle’s NATS (immobilizer system), disconnection of the link between the audio unit and the IMMU will cause the audio unit to switch into the lock (“SECURE”) mode in which the audio unit is fully inoperative. Hence, repair of the audio unit is basically impossible, unless the audio unit is reset to the “NEW” state for which special decoding equipment is required. The radio manufacturer has provided their authorized service representatives with so called “decoder boxes” which can bring the audio unit back to the “NEW” state, enabling the audio unit to be switched on after which repair can be carried out. Subsequently, when the repaired audio unit is delivered to the final user again, it will be in the “NEW” state as to enable re-linking the audio unit to the vehicle’s immobiliser system. As a result of the above, repair of the audio unit can only be done by an authorized representative of the radio manufacturer. Service instruction Item

Radio linked with IMMU and/or SECU

Battery disconnection

No additional action required

Radio needs repair

Repair needs to be done by authorised representative of radio manufacturer since radio cannot be operated unless it is reset to NEW state, using special decoding equipment

Replacement of radio by new part

Radio is delivered in NEW state. If possible, the radio will automatically link up with the immobiliser system. If this appears not possible, the audio unit code needs to be manually input

Transferring radio to another vehicle / replacement of radio by an ‘‘old’’part

Radio needs to be reset to NEW state by authorised representative of radio manufacturer

Replacement of IMMU by new part

Radio will request for the audio unit code input prior to establishing the link with the IMMU

Replacement of IMMU by old part

If a radio code has already been stored in memory of the IMMU, the radio cannot be linked to it. After switching on the radio, it will display ‘‘SECURE’’ after 1 minute. Operation can only be established after resetting the ratio by an authorised representative of radio manufacturer

No communication from IMMU to radio

Radio will display ‘‘SECURE’’ after 180 attempts to communicate with IMMU. Further use of radio impossible until communication is established again, or after radio is reset by authorised representative of (radio) manufacturer

EL-216

AUDIO Anti-theft System (Cont’d) Audio unit code input procedure 1. Radio displays “CODE IN” after the power is switched ON. 2. Enter the audio unit code (4−digits) by pressing the preset buttons (using 1 to 4). Press the preset buttons for the necessary amount of times for the number of each digits. e.g. the audio unit code is “5432” Press No. 1 preset button for 5 times Press No. 2 preset button for 4 times Press No. 3 preset button for 3 times Press No. 4 preset button for 2 times 3. Press the button. 4. If the code is OK, the radio will power ON. If the code is NG, the radio will be locked up as below. After the lock up, the radio will display “CODE IN” again. 1st to 3rd attempt: The radio will be locked for 10 seconds after each attempt 4th to 20th attempt: The radio will be locked for 60 minutes after each attempt Over 20th attempt: The radio will be locked completely

Speed Dependent Volume Control Description If activated, the radio output volume will be automatically adjusted to compensate for increasing driving noises at higher driving speeds. The radio receives a speed signal from the vehicle speed sensor (VSS) and selects the output volume.

Personal Audio Settings Description The radio is designed to store several settings (volume, bass, treble, preset stations and level of speed dependent volume control) with every NATS ignition key used. Up to a maximum of 4 NATS keys can be registered. During the communication as mentioned under “Anti-theft System”, the radio will recognize the used ignition key and select the accompanying settings.

EL-217

: RHD models : With steering wheel switch : With daytime light system : Without daytime light system : With CD auto changer

IGNITION SWITCH ACC or ON COMBINATION SWITCH (LIGHTING SWITCH)

FUSE

FUSE

CD AUTO CHANGER

BATTERY

FUSE

COMBINATION METER (SPEEDOMETER) ROOF ANTENNA

DT AUDIO

SOURCE SWITCH SEEK UP SWITCH VOLUME SWITCH

SPIRAL CABLE

SEEK DOWN SWITCH SPECIAL SWITCH AUDIO STEERING WHEEL SWITCH

FRONT SPEAKER LH

TWEETER LH

FRONT SPEAKER RH

TWEETER RH

REAR SPEAKER LH

REAR SPEAKER RH

NATS IMMU

DONGLE CONTROL UNIT

AUDIO

DAYTIME LIGHT CONTROL UNIT

Schematic

EL-218

.

YEL184C

AUDIO Wiring Diagram — AUDIO —

YEL888C

EL-219

AUDIO Wiring Diagram — AUDIO — (Cont’d) BATTERY : LHD models : RHD models : With daytime light system : Without daytime light system

OFF

1ST

2ND

COMBINATION SWITCH (LIGHTING SWITCH)

FUSE BLOCK (J/B)

AUDIO

DAYTIME LIGHT CONTROL UNIT

FRONT SPEAKER LH

FRONT SPEAKER LH

TWEETER LH

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL186C

EL-220

AUDIO Wiring Diagram — AUDIO — (Cont’d) AUDIO : LHD models : RHD models

FRONT SPEAKER RH

FRONT SPEAKER RH

TWEETER RH

YEL187C

EL-221

AUDIO Wiring Diagram — AUDIO — (Cont’d) AUDIO : 4 door models and 5 door hatchback models : Wagon models

REAR SPEAKER LH

REAR SPEAKER LH

YEL188C

EL-222

AUDIO Wiring Diagram — AUDIO — (Cont’d) DONGLE CONTROL UNIT

NATS IMMU

: RHD models : With steering wheel switch ROOF ANTENNA

AUDIO

SPIRAL CABLE

AUDIO STEERING WHEEL SWITCH

SOURCE SWITCH

SEEK UP SWITCH

VOLUME SWITCH

SEEK DOWN SWITCH

SPECIAL SWITCH

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL217C

EL-223

AUDIO Wiring Diagram — AUDIO — (Cont’d)

AUDIO

To ELAUDIO-01

CD AUTO CHANGER

YEL189C

EL-224

AUDIO Wiring Diagram — AUDIO — (Cont’d)

AUDIO

CD AUTO CHANGER

YEL190C

EL-225

AUDIO Trouble Diagnoses Symptom

Possible cause

Repair order

Radio inoperative (no digital 1. 10A Fuse display and no sound from speakers). 2. Poor radio case ground 3. Radio

1. Check 10A fuse [No. 3 , located in fuse block (J/B)]. Turn ignition switch ON and verify battery positive voltage is present at terminal 쑗 3 of radio 2. Check radio case ground. 3. Remove radio for repair.

1. Radio output Radio controls are operational, but no sound is 2. Radio heard from any speaker.

1. Check radio output voltages. 2. Remove radio for repair.

Radio presets are lost when ignition switch is turned OFF.

1. 15A fuse

1. Check 15A fuse [No. 35 , located in fuse and fusible box and verify battery positive voltage is present at terminal 쑗 9 of radio. 2. Remove radio for repair.

2. Radio Individual speaker is noisy or inoperative.

4. Radio

1. Check speaker 2. Check radio output voltages. 3. Check wires for open or short between radio and speaker. 4. Remove radio for repair.

Radio stations are weak or noisy.

1. Antenna 2. Poor radio ground 3. Radio

1. Check antenna. 2. Check radio ground. 3. Remove radio for repair.

Radio generates noise in AM and FM modes with engine running.

1. Poor radio ground 2. Loose or missing ground bonding straps 3. Ignition condenser or rear window defogger noise suppressor condenser 4. Alternator 5. Ignition coil or secondary wiring 6. Radio

1. Check radio ground. 2. Check ground bonding straps.

1. Poor radio ground 2. Antenna 3. Accessory ground 4. Faulty accessory

1. Check radio ground. 2. Check antenna. 3. Check accessory ground. 4. Replace accessory.

Radio generates noise in AM and FM modes with accessories on (switch pops and motor noise).

1. Speaker 2. Radio output 3. Speaker circuit

EL-226

3. Replace ignition condenser or rear window defogger noise suppressor condenser. 4. Check alternator 5. Check ignition coil and secondary wiring. 6. Remove radio for repair.

AUDIO Trouble Diagnoses (Cont’d) CD AUTOCHANGER Symptom No play of the CD after CD play button is pushed.

Possible cause 1. Radio (The radio is not working.) 2. Harness connection (Magazine does not eject.) 3. Discs 4. Magazine does not eject or a disc remains in CD player. 5. Changer

CD skipping.

1. Rough road driving 2. Discs 3. Bracket 4. Changer

Error code [NO DISC] is shown on the radio after CD play button is pressed.

1. Magazine setting 2. Magazine

Repair order 1. Remove the radio for repair. 2. Check harness connection. 3. Inspect disc. (Refer to testing magazines and discs.) 4. Reset the changer. (Disconnect harness connector at the changer and reconnect after 30 sec.) 5. Remove the changer for repair. 1. System is not malfunctioning. 2. Inspect discs. (Refer to testing magazines and discs.) 3. Check and repair bracket and installation of changer. 4. Remove the changer for repair. 1. Confirm the magazine is pushed completely. 2. Inspect magazine. (Refer to testing magazines and discs.) 3. Remove the changer for repair.

3. Changer

Testing magazines and discs 1. Confirm discs are installed correctly into the magazine (not upside down). 2. Visually inspect/compare the customer’s discs with each other and other discs. Identify any of the following conditions: ● Discs with a large outside diameter. [Normal size is 120 mm (4.72 in).] ● Discs with rough or lipped edges. ● Discs with excessive thickness [Normal size is 1.2 mm (0.047 in).] ● Discs with scratches, abrasions, or pits on the surface. ● Discs with grease/oil, fingerprints, foreign material. ● Discs are warped due to excessive heat exposure. 3. Slide/place the discs in and out of the various magazine positions. Identify any discs and/or positions that require additional force for placement/ejection. If interference (sticking, excessive tensions) is found, replace the magazine or the discs. Note: ● Discs which are marginally out of specification (ex. dirty, scratched and so on) may play correctly on a home stereo. However, when used in the automative environment skipping may occur due to the added vehicle movement and/or vibration due to road conditions. Autochangers should not be replaced when discs are at fault. ● Use a soft damp cloth to wipe the discs starting from the center outward in radial direction. Never use chemical cleaning solutions to clean the discs.

EL-227

AUDIO Inspection SPEAKER 1. Disconnect speaker harness connector. 1 and 쑗 2 . 2. Measure the resistance between speaker terminals 쑗 ● The resistance should be 2 - 4Ω. 3. Using jumper wires, momentarily connect a 9V battery between speaker terminals ● A momentary hum or pop should be heard.

1 쑗

and

2 . 쑗

ANTENNA Using a jumper wire, clip an auxiliary ground between antenna and body. ● If reception improves, check antenna ground (at body surface). ● If reception does not improve, check main feeder cable for short circuit or open circuit.

RADIO All voltage inspections are made with: ● Ignition switch ON or ACC ● Radio ON ● Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)

EL-228

AUDIO ANTENNA Location of Antenna

NEL769

EL-229

ELECTRIC SUNROOF Wiring Diagram — SROOF — IGNITION SWITCH ON or START

BATTERY

FUSE BLOCK (J/B)

Refer to EL-POWER.

POWER WINDOW RELAY

CIRCUIT BREAKR-1

: LHD models : RHD models

SUNROOF SWITCH OPEN

CLOSE

OPEN

CLOSE

SUNROOF MOTOR

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL191C

EL-230

POWER DOOR MIRROR Wiring Diagram — MIRROR — LHD models ★ For removal of door mirror, refer to “DOOR MIRROR” in BT section.

YEL890C

EL-231

POWER DOOR MIRROR Wiring Diagram — MIRROR — (Cont’d) RHD models

YEL891C

EL-232

POWER SEAT Power Seat/Wiring Diagram — SEAT —

YEL892C

EL-233

HEATED SEAT Heated Seat/Wiring Diagram — HSEAT — ★ For location of heating unit, refer to “SEAT” in BT section. IGNITION SWITCH ON or START FUSE BLOCK (J/B)

HIGH

LOW

OFF

HIGH HIGH

HIGH

OFF

Refer to EL-POWER

LOW

OFF

HEATED SEAT SWITCH LH

INDICATOR LAMP

HIGH

LOW

OFF

LOW

HIGH

OFF

HIGH

LOW

OFF

HEATED SEAT SWITCH RH

INDICATOR LAMP

Next page

Next page

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B)

YEL195C

EL-234

HEATED SEAT Heated Seat/Wiring Diagram — HSEAT — (Cont’d)

Preceding page

Preceding page

THERMOSTAT SWITCH

HEATED SEAT RH

HEATED SEAT LH THERMOSTAT SWITCH

YEL196C

EL-235

POWER WINDOW System Description Power is supplied at all times ● from 40A fusible link (Letter e , located in the fusible link and fuse box) ● through circuit breaker-1 ● to power window relay. With ignition switch in ON or START position, power is supplied ● to power window relay. Ground is supplied to power window relay ● through body grounds M6 , M28 and M26 . The power window relay is energized and power is supplied ● through power window relay. ● to power window main switch terminal 쑗 12 , ● to passenger side power window sub-switch terminal 쑗 5 , ● to rear power window sub-switch LH terminal 쑗 5 , ● to rear power window sub-switch RH terminal 쑗 5 .

MANUAL OPERATION Driver’s door Ground is supplied ● to front power window main switch terminals ● through body grounds B18 and B27 .

2 쑗

WINDOW UP When a driver side switch in the power window main switch is pressed in the up position, power is supplied ● to driver side power window regulator terminal 쑗 1 ● through power window main switch terminal 쑗 3 . Ground is supplied ● to driver side power window regulator terminal 쑗 2 ● through power window main switch terminal 쑗 4 . Then, the motor raises the window until the switch is released. WINDOW DOWN When a driver side switch in the power window main switch is pressed in the down position, power is supplied ● to driver side power window regulator terminal 쑗 2 ● through power window main switch terminal 쑗 4 . Ground is supplied ● to driver side power window regulator terminal 쑗 1 ● through power window main switch terminal 쑗 3 . Then, the motor lowers the window until the switch is released.

Except driver’s door Ground is supplied ● to power window main switch terminal ● through body grounds B18 and B27 .

2 쑗

EL-236

POWER WINDOW System Description (Cont’d) PASSENGER’S DOOR NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch. Power is supplied ● through power window main switch (쑗 6 , 쑗 10 ) ● to passenger side power window sub-switch (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through passenger side power window sub-switch (쑗 2 , 쑗 4 ) ● to passenger side power window regulator (쑗 1 , 쑗 2 ). Ground is supplied ● to passenger side power window regulator (쑗 2 , 쑗 1 ) ● through passenger side power window sub-switch (쑗 2 , 쑗 4 ) ● to passenger side power window sub-switch (쑗 1 , 쑗 3 ) ● through power window main switch (쑗 6 , 쑗 10 ). Then, the motor raises or lowers the window until the switch is released. REAR DOOR LH NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch Power is supplied ● through power window main switch (쑗 13 , 쑗 14 ) ● to rear power window sub-switch LH (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through rear power window sub-switch LH (쑗 2 , 쑗 4 ) ● to rear power window regulator LH (쑗 1 , 쑗 2 ). Ground is supplied ● to rear power window regulator LH (쑗 2 , 쑗 1 ) ● through rear power window sub-switch LH (쑗 4 , 쑗 2 ) ● to rear power window sub-switch LH (쑗 1 , 쑗 3 ) ● through power window main switch LH (쑗 14 , 쑗 13 ). Then, the motor raises or lowers the window until the switch is released.

EL-237

POWER WINDOW System Description (Cont’d) REAR DOOR RH NOTE: Figures in parentheses ( ) refer to terminal Nos. arranged in order when the UP or DOWN section of power window switch is pressed. Operation by main switch Power is supplied ● through power window main switch (쑗 15 , 쑗 16 ) ● to rear power window sub-switch RH (쑗 3 , 쑗 1 ). The subsequent operations are the same as those outlined under “Operation by sub-switches”. Operation by sub-switches Power is supplied ● through rear power window sub-switch RH (쑗 2 , 쑗 4 ) ● to rear power window regulator RH (쑗 1 , 쑗 2 ). Ground is supplied ● to rear power window regulator RH (쑗 2 , 쑗 1 ) ● through rear power window sub-switch RH (쑗 4 , 쑗 2 ) ● to rear power window sub-switch RH (쑗 1 , 쑗 3 ) ● through power window main switch (쑗 16 , 쑗 15 ) Then, the motor raises or lowers the window until the switch is released.

AUTO OPERATION The power window AUTO feature enables the driver to open or close the driver’s window without holding the window switch in the respective position. When the AUTO switch in the main switch is pressed and released, the driver’s window will travel to the fully open or closed position.

POWER WINDOW LOCK The power window lock is designed to lock-out window operation to all windows except the driver’s door window. When the lock switch is pressed to lock position, ground of the passenger side switch, rear RH switch and rear LH switch in the power window main switch is disconnected. This prevents the power window motors from operating.

EL-238

IGNITION SWITCH ON or START

BATTERY (Via fusible link)

: With rear power window

FUSIBLE LINK

CIRCUIT BREAKER-1 POWER WINDOW MAIN SWITCH

DRIVER’S SIDE

LOCK SWITCH

PASSENGER SIDE

REAR LH

REAR RH

POWER WINDOW RELAY

FRONT POWER WINDOW SUB-SWITCH

AUTO AMP.

UP RELAY

DOWN RELAY

REAR POWER WINDOW SUB-SWITCH RH

REAR POWER WINDOW REGULATOR RH

ILL

FRONT POWER WINDOW REGULATOR (DRIVER’S SIDE)

POWER WINDOW

REAR POWER WINDOW REGULATOR LH

Schematic

EL-239

REAR POWER WINDOW SUB-SWITCH LH

FRONT POWER WINDOW REGULATOR (PASSENGER’S SIDE)

YEL197C

POWER WINDOW Wiring Diagram — WINDOW —

YEL894C

EL-240

POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)

YEL895C

EL-241

POWER WINDOW Wiring Diagram — WINDOW — (Cont’d)

YEL896C

EL-242

POWER WINDOW Trouble Diagnoses Symptom None of the power windows can be operated using any switch.

Possible cause 1. 40A fusible link and circuit breaker-1.

Repair order 1. Check 40A fusible link (letter e , located in fuse and fusible link box) and circuit breaker-1. Turn ignition switch to “ON” position and verify battery positive voltage is present at terminal 쑗 12 of power window main switch, and other switches as follows. Location of sub-switch

Terminals

Passenger Rear RH Rear LH

5 쑗 5 쑗 5 쑗

2. Grounds B18 and B27 . 3. Power window relay. 4. Open/short in power window main switch circuit.

2. Check grounds B18 and B27 . 3. Check power window relay. 4. Check W/R wire between fuse block (J/B) and power window main switch for open/short circuit.

Driver’s side power window cannot be operated but other windows can be operated.

1. Driver’s side power window regulator circuit. 2. Driver’s side power window regulator.

1. Check driver’s side power window regulator circuit

One or more passenger power windows cannot be operated.

1. Power window switches (front sub-switch, rear sub-switch RH, rear sub-switch LH). 2. Power window regulators. (Passenger side, rear LH, rear LH.) 3. Power window main switch. 4. Power window circuit.

1. Check power window switches (front sub-switch, rear sub-switch RH, rear sub-switch LH)

1. Power window main switch.

1. Check power window main switch.

Driver’s side power window auto 1. Power window main switch. function cannot be operated using power window main switch.

1. Check power window main switch.

One or more passenger power windows cannot be operated using power window main switch but can be operated by power window sub-switches.

EL-243

2. Check driver’s side power window regulator

2. Check power window regulators (front sub-switch, rear sub-switch RH, rear sub-switch LH) 3. Check power window main switch 4-1. Check harnesses between power window main switch and power window sub-switches for open/short circuit. 4-2. Check harnesses between power window subswitches and power window regulators for open/ short circuit.

POWER WINDOW NOTE

EL-244

POWER DOOR LOCK System Description/Door Lock for LHD Models OPERATION Power door lock/unlock operation by door key cylinder ● With the key inserted into front door key cylinder, turning it to LOCK will lock all doors. ● With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors. Power door lock/unlock operation by multi-remote controller (If equipped) ● Pressing multi-remote controller LOCK button will lock all doors. ● Pressing multi-remote controller UNLOCK button once will unlock driver door. Then, if an unlock signal is sent from the remote controller again within 5 seconds, all other doors will be unlocked. Power door lock/unlock operation by lock/unlock switch ● With lock/unlock switch on driver door trim setting to LOCK will lock all doors. ● With lock/unlock switch on driver door trim setting to UNLOCK will unlock all doors. Key reminder system ● If the ignition key is in the ignition key cylinder and driver door is open, setting lock/unlock switch, lock knob, key or multi-remote controller to “LOCK” locks the door once but then immediately unlocks all doors. (signal from door unlock sensor driver side)

EL-245

POWER DOOR LOCK Schematic

YEL897C

EL-246

POWER DOOR LOCK Schematic (Cont’d)

YEL898C

EL-247

POWER DOOR LOCK Wiring Diagram — D/LOCK —

YEL899C

EL-248

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL900C

EL-249

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL901C

EL-250

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL902C

EL-251

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL903C

EL-252

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL904C

EL-253

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL905C

EL-254

POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d)

YEL906C

EL-255

POWER DOOR LOCK Trouble Diagnoses PRELIMINARY CHECK CHECK-IN 왔

Open all windows and remove key from ignition key cylinder. 왔

Does power door lock operate properly?

No (All doors)

왘

Power door lock does not operate by using; — any switch. ...................................................................... — driver side lock knob switch and/or key cylinder. ...................................................................... — passenger side lock knob switch and/or key cylinder.★

Yes

왘

SYMPTOM 1

왘

SYMPTOM 2

왘

SYMPTOM 3

No (Specific door)

SYMPTOM 4

왔

Insert key to ignition key cylinder, open any door and lock the door using driver side knob lock switch. 왔

Does key reminder system operate properly? 왔

No

왘

SYMPTOM 5

Yes

INSPECTION END

After performing preliminary check, go to symptom chart on the next page. ★ When one or more doors are opened, with lock knob on passenger door setting to LOCK, will lock passenger door only. (Power door lock system will not operate.)

EL-256

POWER DOOR LOCK Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-256. Symptom numbers in the symptom chart correspond with those of Preliminary check.

Power door lock does not operate with lock/unlock switch.

3

Power door lock does not operate with door key cylinder switch.

4

Specific door lock acutator does not operate.

5

*Key reminder system does not operate.

EL-262

EL-263

Procedure 5 (Key switch check)

2

EL-261

Procedure 4 (Door switch check)

Power door lock does not operate using any switch.

EL-260

Procedure 3 (Door lock actuator check)

1

EL-259

Procedure 2 (Door key cylinder switch check)

SYMPTOM

EL-258

Procedure 1 (Door unlock sensor check)

REFERENCE PAGE

Power supply and ground circuit check

SYMPTOM CHART

X

X

X

X X X X

X: Applicable *: Make sure the power door lock and key reminder system operate properly.

EL-257

POWER DOOR LOCK Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector

Terminals 䊝 9 쑗

Ignition switch position 䊞

LOCK

ACC

ON

Ground

Battery voltage

Battery voltage

Battery voltage

YEL445B

Ground circuit check Time control unit connector

Terminals 16 쑗

- Ground

YEL431B

EL-258

Continuity Yes

POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Door unlock sensor check) Time control unit connector

CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Check voltage between time control unit connector terminals 쑗 35 or 쑗 36 and ground. Terminals

YEL446B

䊝

Driver side

35 쑗

Passenger side

36 쑗

䊞

Condition

Voltage [V]

Locked

Approx. 2 (Approx. 20 sec.)

Unlocked

0

Locked

Approx. 12 (Approx. 20 sec.)

Unlocked

0

Ground

Ground

OK

왘

Door unlock sensor is OK.

왘

Replace door lock actuator assembly.

YEL027D

NG 왔

CHECK DOOR UNLOCK SENSOR. 1) Disconnect door unlock sensor connector. 2) Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗

Condition

Continuity

Locked

No

Unlocked

Yes

OK 왔

Check the following: ● Door unlock sensor ground circuit. ● Harness for open or short-circuit between control unit and door unlock sensor

EL-259

NG

POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Door key cylinder switch check) CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Check voltage between time control unit connector terminal 쑗 29 and ground. Key cylinder switch operation

Voltage [V]

Between neutral and lock

0

Unlock/neutral

Approx. 5

OK

왘

Door key cylinder switch is OK.

왘

Replace key cylinder switch.

NG 왔

YEL028D

CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals. Terminals

Key cylinder switch Driver side

:

Passenger side: 1 -쑗 2 쑗

YEL817

Key position

Continuity

Neutral

No

Between neutral and lock

Yes

Unlock/ neutral

No

Full stroke (Lock)

No

OK 왔

Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.

EL-260

NG

POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals

Knob lock switch condition YEL029D

䊝

䊞

쑗 42 쑗 44 쑗

Ground

41

Unlock , Lock Lock , Unlock

NG

왘

Door lock actuator is OK.

Voltage (V)

Approx. 12 Ground (Approx. 5 seconds) Ground

Before operating passenger side knob lock switch, close all doors. OK 왔

YEL030D

CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals

Door lock actuator operation

YEL031D

䊝

䊞

Unlocked , Locked

6 쑗

3 쑗

Locked , Unlocked

3 쑗

6 쑗

Passenger side Terminals

Door lock actuator operation

䊝

䊞

Unlocked , Locked

3 쑗

6 쑗

Locked , Unlocked

6 쑗

3 쑗

Rear door LH and RH YEL032D

Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

4 : (LH) 쑗 1 : (RH) 쑗 1 : (LH) 쑗 4 쑗 : (RH)

1 : (LH) 쑗 4 : (RH) 쑗 4 : (LH) 쑗 1 쑗 : (RH)

NG 왔

Replace door lock actuator assembly.

EL-261

OK

왘

Check harness between control unit and door lock actuator.

POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 (Door switch check) Fuse block (J/B) connector

CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals YEL450B

Driver side door

Condition

Voltage [V]

Opened

0

OK

왘

Door switch is OK.

16J

Closed

Approx. 12

Other door

Opened

0

Closed

Approx. 12

7J

NG 왔

YEL033D

CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗

Condition

Continuity

Closed

No

Open

Yes

OK 왔

Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch

EL-262

NG

왘

Replace door switch.

POWER DOOR LOCK Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 (Key switch check) CHECK IGNITION KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch

Voltage [V]

Key is inserted

Approx. 12

Key withdrawn

0

YEL034D

OK

왘

Key switch is OK.

NG 왔

Key switch connector

CHECK KEY SWITCH POWER SUPPLY. Check voltage between key switch harness terminal 쑗 2 and ground. Battery voltage should exist.

왔

CHECK KEY SWITCH. 1) Disconnect key switch connector. 2) Check continuity between key switch terminals. Terminals

쑗 쑗 1

YEL827

왘

OK

YEL826

Key switch connector

NG

-

Condition

Continuity

Key is inserted.

Yes

Key is withdrawn.

No

2

OK 왔

Check harness for open or short between control unit and key switch.

EL-263

NG

왘

Check the following. ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse

Replace key switch.

POWER DOOR LOCK NOTE

EL-264

POWER DOOR LOCK — Super Lock — Component Parts Location

Door key cylinder switch Time control unit

Lock knob

Door switch

Door lock actuator assembly Door lock switch

Door key cylinder switch connector D9 , D17 Fuse block (J/B)

Time control unit B11 , B12 , B96

Door lock actuator assembly D7 , D16

NEL562

EL-265

POWER DOOR LOCK — Super Lock — System Description/Super Lock for RHD Models OUTLINE Power door lock system with super lock and key reminder is controlled by time control unit. Super lock has a higher anti-theft performance than conventional power door lock systems. When super lock is in released condition, lock knob operation locks or unlocks door. When super lock is in set condition; lock knob operation cannot lock nor unlock door. With super lock set

With super lock released

Door key cylinder UNLOCK

LOCK

Door lock knob Door knob rod Lever B

Lever B

UNLOCK

With super lock set, the connecting rod is disengaged from lever B. This enables the linkage to convey operational force from lever B to lever A. The door lock knob can still be operated but this operation does not lock nor unlock door.

Connecting rod

LOCK

Door lock actuator assembly Lever A

Door lock actuator assembly Lever A

SEL831U

OPERATION Power door lock/unlock and super lock set/release operation by door key cylinder ● With the key inserted into front door key cylinder, turning it to LOCK will lock all doors and set super lock while all doors are closed or any door is open. (Super lock will not be set while key is inserted in the ignition key cylinder.) ● With the key inserted into front door key cylinder, turning it to UNLOCK will unlock all doors and release super lock. Power door lock/unlock and super lock set/release operation by multi-remote controller (if equipped) ● Pressing multi-remote controller LOCK button will lock all doors and set super lock while all doors are closed and key is not inserted in the ignition key cylinder. ● Pressing once will release super lock and unlock driver’s door. ● Pressing twice will release super lock and unlock all doors. Power door lock and super lock release operation (by NATS IMMU signal) ● When the super lock is set, turning ignition key switch to ON will release super lock and unlock all doors.

EL-266

POWER DOOR LOCK — Super Lock — System Description/Super Lock for RHD Models (Cont’d) Power door lock/unlock operation by lock knob ● With lock knob on driver or passenger door setting to LOCK while all doors are closed will lock all doors. When one or more door is opened, with lock knob on passenger door setting to LOCK will lock passenger door only. (Power door lock system will not operate.) ● With lock knob on driver or passenger door setting to UNLOCK while all doors are closed will unlock all doors. Lock knob operation cannot control super lock. Key reminder system ● If the ignition key is in the ignition key cylinder and any door is open, setting the lock/unlock switch or lock knob on driver or passenger door to “LOCK” locks the door once but then immediately unlocks all doors.

Central unlock/trunk or back door release switch Signal input Short press

Status Long press

DR

AS

RL

RR

Trunk release

U

U

U

U

Trunk release

Trunk release

U

U

U

L

No action

Trunk release

Trunk release

U

U

L

U

No action

Central unlock (not DR door)

Trunk release

Central unlock (not DR door) + Trunk release

U

U

L

L

DR and AS doors unlocked

Central unlock (not DR door)

Central unlock (not DR door)

Central unlock (not DR door) + Trunk release

Central unlock (not DR door) + Trunk release

U

L

X

X

DR door unlocked, AS door locked

Central unlock

Central unlock

Central unlock + Trunk release

Central unlock + Trunk release

L

L

X

X

Both front doors locked

No action

No action

No action

No action

L

L

L

L

Super locked

Without ultra sonic With ultra sonic

Without ultra sonic With ultra sonic

No action

No action

Trunk release

No action

No action

No action

Fully unlocked

U: Unlocked; L: locked; X: Don’t care

System initialisation ● System initialisation is required when battery cables are reconnected. Conduct one of the followings to release super lock once; — insert the key into ignition key cylinder and turn it to ON. — LOCK/UNLOCK operation using door key cylinder.

EL-267

POWER DOOR LOCK — Super Lock — Schematic

YEL907C

EL-268

POWER DOOR LOCK — Super Lock — Schematic (Cont’d)

UNLOCK

LOCK

RELEASE

UNLOCK

UNLOCK

UNLOCK SENSOR

SET

LOCK

SUPER LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE)

DOOR LOCK ACTUATOR

LOCK UNLOCK SENSOR

RELEASE

UNLOCK

RELEASE

SET

SUPER LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE)

LOCK DOOR LOCK ACTUATOR

SET

UNLOCK

LOCK

RELEASE

SET

UNLOCK

LOCK

UNLOCK

LOCK

SUPER LOCK ACTUATOR

DOOR LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY REAR LH

SUPER LOCK ACTUATOR

DOOR LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY REAR RH

: 4 door models and 5 door hatchbak models : Wagon models

DOOR LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY (BACK DOOR)

YEL325B

EL-269

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK —

YEL908C

EL-270

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)

YEL909C

EL-271

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)

YEL910C

EL-272

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)

EL-S/LOCK-04 TIME CONTROL UNIT

B12 35

36

Y/R

Y/L

Y/L

Y/R B5

B56

1

3

D11

D2 Y/R

Y/L

Y/R

Y/L

5

5 DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) (UNLOCK SENSOR)

UNLOCK

UNLOCK

D7

LOCK

D16

LOCK

2

2

B

B

B

B D11

D2 4

11 B

1 2 3 4 5 6 7 8 9 10 11 12

DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) (UNLOCK SENSOR)

B5

B

B

B

B18

B27

B56

B5 W

1 2 3 4 B56 5 6 7 8 9 10 W

1 2 3 4 5 6

D7 B

3 2 1 6 5 4

D16 B

24 23 22 21 20 19 18 17 B12 36 35 34 33 32 31 30 29 28 27 26 25 W

YEL329B

EL-273

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator

YEL911C

EL-274

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator

: RHD models Preceding page Next page

Next page Preceding page

DOOR LOCK ACTUATOR UNLOCK

LOCK

SUPER LOCK ACTUATOR SET

DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE)

DOOR LOCK ACTUATOR LOCK

RELEASE

UNLOCK

SUPER LOCK ACTUATOR

DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE)

RELEASE SET

YEL277C

EL-275

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-1 for Super Lock Actuator

YEL913C

EL-276

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator

YEL914C

EL-277

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator

YEL915C

EL-278

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) Type-2 for Super Lock Actuator

YEL916C

EL-279

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d) WAGON MODELS

YEL917C

EL-280

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)

YEL918C

EL-281

POWER DOOR LOCK — Super Lock — Wiring Diagram — S/LOCK — (Cont’d)

YEL919C

EL-282

POWER DOOR LOCK — Super Lock — Trouble Diagnoses PRELIMINARY CHECK CHECK-IN 왔

Open all windows and remove key from ignition key cylinder. 왔

Does power door lock operate properly?

No (All doors)

왘

Power door lock does not operate by using; — any switch. ...................................................................... — driver side lock knob switch and/or key cylinder. ...................................................................... — passenger side lock knob switch and/or key cylinder.★

Yes

왘

SYMPTOM 1

왘

SYMPTOM 2

왘

SYMPTOM 3

No (Specific door) 왔

No (All doors)

Does super lock set by using door key cylinder?

SYMPTOM 4

왘

Super lock does not set by using; — both door key cylinders. ...................................................................... — one of door key cylinders.

Yes

왘

SYMPTOM 5

왘

SYMPTOM 6

No (Specific door) 왔

Does super lock release by using door key cylinder or IGN key switch?

No All doors

SYMPTOM 9

왘

Super lock does not release by using; — one or both door key cylinders. ...................................................................... — IGN key switch. (Signal from NATS IMMU)

Yes

왘

SYMPTOM 7

왘

SYMPTOM 8

No (Specific door)

SYMPTOM 9

왔

Insert key to ignition key cylinder, open any door and lock the door using driver side knob lock switch. 왔

Does key reminder system operate properly? 왔

No

왘

SYMPTOM 10

Yes

INSPECTION END

After performing preliminary check, go to symptom chart on the next page. ★ When one or more doors are opened, with lock knob on passenger door setting to LOCK, will lock passenger door only. (Power door lock system will not operate.)

EL-283

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-283. Symptom numbers in the symptom chart correspond with those of Preliminary check.

SYMPTOM CHART

X

3

Power door lock does not operate with any switch of passenger side.

X

4

Specific door lock acutator does not operate.

5

Super lock cannot be set by both door key cylinders.

6

Super lock cannot be set by one of door key cylinders.

7

*Super lock cannot be released by one or both door key cylinders.

8

*Super lock cannot be released by ignition key switch. (Signal from NATS IMMU)

9

Specific super lock actuator does not operate.

10

*Key reminder system does not operate.

Procedure 6 (NATS release signal check)

Procedure 5 (Door switch check)

Procedure 8 (Ignition switch “ON” circuit check)

Power door lock does not operate with any switch of driver side.

Procedure 7 (Key switch check)

2

Procedure 4 (Super lock actuator check)

X

Power door lock does not operate using any switch.

EL-288, EL-290, EL-292, EL-294 EL-295 EL-295 289 291 293

Procedure 3 (Door lock actuator check)

X

1

Procedure 2 (Door key cylinder switch check)

Procedure 1 (Door unlock sensor check)

SYMPTOM

EL-285 EL-286 EL-287 Power supply and ground circuit check

REFERENCE PAGE

X

X

X

X X

X

X

X

X X

X

X X

X: Applicable *: Make sure the power door lock and key reminder system operate properly.

EL-284

X

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector

Terminals

Ignition switch position

䊝

䊞

LOCK

ACC

ON

9 쑗

Ground

Battery voltage

Battery voltage

Battery voltage

YEL445B

Ground circuit check Time control unit connector

Terminals 16 쑗

- Ground

YEL431B

EL-285

Continuity Yes

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (Door unlock sensor check) Time control unit connector

CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Check voltage between time control unit connector terminals 쑗 35 or 쑗 36 and ground. Terminals

YEL446B

䊝

Driver side

Door lock actuator assembly connectors Driver side :

35 쑗

䊞

36 쑗

Voltage [V]

Locked

Approx. 2 (Approx. 20 sec.)

Unlocked

0

Locked

Approx. 12 (Approx. 20 sec.)

Unlocked

0

Ground

Passenger side:

Passenger side

Condition

Ground

OK

왘

Door unlock sensor is OK.

왘

Replace door lock actuator assembly.

YEL815

NG 왔

CHECK DOOR UNLOCK SENSOR. 1) Disconnect door unlock sensor connector. 2) Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗

Condition

Continuity

Locked

No

Unlocked

Yes

OK 왔

Check the following: ● Door unlock sensor ground circuit. ● Harness for open or short-circuit between control unit and door unlock sensor

EL-286

NG

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Door key cylinder switch check) CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Check voltage between time control unit connector terminal 쑗 29 and ground. Key cylinder switch operation

Voltage [V]

Between neutral and lock

0

Unlock/neutral

Approx. 5

OK

왘

Door key cylinder switch is OK.

왘

Replace key cylinder switch.

NG 왔

YEL028D

CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals. Terminals

Key cylinder switch Driver side

:

Passenger side: 1 -쑗 2 쑗

YEL817

Key position

Continuity

Neutral

No

Between neutral and lock

Yes

Unlock/ neutral

No

Full stroke (Lock)

No

OK 왔

Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.

EL-287

NG

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 — Type-1 for Super Lock Actuator — (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals

Knob lock switch condition YEL029D

Unlock , Lock Lock , Unlock

䊝

䊞

41 쑗 42 쑗 44 쑗

NG

왘

Door lock actuator is OK.

왘

Check harness between control unit and door lock actuator.

Voltage (V)

Ground

Approx. 12 Ground (Approx. 5 seconds) Ground

Before operating passenger side knob lock switch, close all doors. OK 왔

YEL035D

CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

1 : 쑗 (RHD)

4 : (RHD) 쑗

4 : (RHD) 쑗 1 : (RHD) 쑗

YEL036D

Passenger side Door lock actuator assembly connector

Rear door RH

Rear door LH

Terminals

Door lock actuator operation

䊝

䊞

Unlocked , Locked

4 : (RHD) 쑗 1 : (RHD) 쑗

Locked , Unlocked

1 : (RHD) 쑗 4 : (RHD) 쑗

Rear door YEL820

Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 쑗 : (RHD)

쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 쑗 : (RHD)

6 : (LHD)

왔

3 : (LHD)

NG

Replace door lock actuator assembly.

EL-288

OK

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 — Type-2 for Super Lock Actuator — (Door lock actuator check) CHECK DOOR LOCK ACTUATOR CIRCUIT. Check voltage for door lock actuator. Terminals

Knob lock switch condition YEL029D

LHD model

Door lock actuator assembly connector Driver side:

Unlock , Lock RHD model

Lock , Unlock

䊝 41 쑗 42 쑗 44 쑗

䊞

NG

왘

Door lock actuator is OK.

왘

Check harness between control unit and door lock actuator.

Voltage (V)

Ground

Approx. 12 Ground (Approx. 5 seconds) Ground

Before operating passenger side knob lock switch, close all doors. OK 왔

YEL819

CHECK DOOR LOCK ACTUATOR. 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. Driver side Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗

3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗

YEL022AA

Passenger side Door lock actuator assembly connector

Rear door RH

Rear door LH

Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗

6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗

Rear door YEL820

Terminals

Door lock actuator operation Unlocked , Locked Locked , Unlocked

䊝

䊞

6 : (LHD) 쑗 1 : (RHD) 쑗 3 : (LHD) 쑗 4 : (RHD) 쑗

3 : (LHD) 쑗 4 : (RHD) 쑗 6 : (LHD) 쑗 1 : (RHD) 쑗

왔

NG

Replace door lock actuator assembly.

EL-289

OK

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 — Type-1 for Super Lock Actuator — (Super lock actuator check) Time control unit connector

CHECK SUPER LOCK ACTUATOR CIRCUIT. Check voltage for super lock actuator. Door key cylinder switch condition YEL449B

Terminals

䊝

䊞

Lock (Set)

40 쑗

Ground

Unlock (Released)

44 쑗

Ground

Super lock actuator is OK.

왘

Check harness between control unit and door lock actuator assembly.

Voltage (V)

Approx. 12

OK

RHD model 왔

CHECK SUPER LOCK ACTUATOR. 1. Disconnect door lock actuator assembly connector. 2. Set lever A in lock position. 3. Apply 12V direct current to door lock actuator assembly and check operation. Driver side Super lock actuator operation

Lever B

Terminals

䊝

䊞

Connection from lever A to lever B

Front

Door lock actuator assembly

Released , Set

6 : (RHD) 쑗 3 : (RHD) 쑗

Disconnect

Set , Released

3 : (RHD) 쑗 6 : (RHD) 쑗

Connect

NEF767

Passenger side Door lock actuator assembly connector Passenger side:

왘

Note: Put the system in set condition before checking release signal.

Door lock actuator assembly connector Driver side:

Lock lever A

NG

Super lock actuator operation

RHD model

Terminals

䊝

䊞

Connection from lever A to lever B

Released , Set

3 : (RHD) 쑗 6 : (RHD) 쑗

Disconnect

Set , Released

6 : (RHD) 쑗 3 : (RHD) 쑗

Connect

Rear door NEF768

Door lock actuator assembly connector

Super lock actuator operation

Rear door RH Rear door LH

Released , Set Set , Released

Terminals

䊝

䊞

1 : (LH) 쑗 6 : (RH) 쑗 4 : (LH) 쑗 3 : (RH) 쑗

4 : (LH) 쑗 3 : (RH) 쑗 1 : (LH) 쑗 6 : (RH) 쑗 왔

Connection from lever A to lever B Disconnect Connect

NG

Replace door lock actuator assembly. YEL255A

EL-290

OK

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 — Type-2 for Super Lock Actuator — (Super lock actuator check) Time control unit connector

CHECK SUPER LOCK ACTUATOR CIRCUIT. Check voltage for super lock actuator. Door key cylinder switch condition YEL449B

䊝

䊞

Lock (Set)

40 쑗

Ground

Unlock (Released)

44 쑗

Ground

Lever B Front

Lock Lever A

Super lock actuator operation Released , Set

Door lock actuator assembly

Door lock actuator assembly

Set , Released YEL822

Terminals

䊝

䊞

1 : (LHD) 쑗 6 쑗 : (RHD) 4 : (LHD) 쑗 3 : (RHD) 쑗

4 : (LHD) 쑗 3 쑗 : (RHD) 1 : (LHD) 쑗 6 : (RHD) 쑗

Connection from lever A to lever B Disconnect Connect

Passenger side

LHD model

Door lock actuator assembly connector Passenger side:

Check harness between control unit and door lock actuator assembly.

OK CHECK SUPER LOCK ACTUATOR. 1. Disconnect door lock actuator assembly connector. 2. Set lever A in lock position. 3. Apply 12V direct current to door lock actuator assembly and check operation. Driver side

Lock Lever A

왘

Voltage (V)

왔

Front

Super lock actuator is OK.

Approx. 12

RHD model

Lever B

왘

Note: Put the system in set condition before checking release signal.

Door lock actuator assembly connector Driver side: LHD model

Terminals

NG

RHD model

Super lock actuator operation Released , Set Set , Released

Terminals

䊝

䊞

4 : (LHD) 쑗 3 쑗 : (RHD) 1 : (LHD) 쑗 6 : (RHD) 쑗

1 : (LHD) 쑗 6 쑗 : (RHD) 4 : (LHD) 쑗 3 : (RHD) 쑗

Connection from lever A to lever B Disconnect Connect

Rear door YEL023A

Door lock actuator assembly connector

Super lock actuator operation

Rear door RH Rear door LH

Released , Set Set , Released

Terminals

䊝

䊞

1 : (LH) 쑗 6 : (RH) 쑗 4 : (LH) 쑗 3 : (RH) 쑗

4 : (LH) 쑗 3 : (RH) 쑗 1 : (LH) 쑗 6 : (RH) 쑗 왔

Connection from lever A to lever B Disconnect Connect

NG

Replace door lock actuator assembly. YEL255A

EL-291

OK

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 — With driver door switch type-1 — (Door switch check) Fuse block (J/B) connector

CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals

YEL450B

Door switch connector Driver side:

Driver side door

16J

Other door

7J

Condition

Voltage [V]

Opened

0

Closed

Approx. 12

Opened

0

Closed

Approx. 12

OK

왘

Door switch is OK.

NG 왔

YEL831

CHECK GROUND CIRCUIT. 1) Disconnect driver side door switch connector. 2) Check harness continuity between terminal 쑗 2 and ground. Continuity should exist.

Door switch connector Driver side:

NG

왘

Repair harness or connector.

OK 왔

CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals Condition Driver side door switch

Door switch connector Passenger side:

Other door switches

Rear side:

2 -쑗 3 쑗 1 쑗 ground

Continuity

Closed

No

Open

Yes

Closed

No

Open

Yes

OK 왔 YEL830

Check the following. ● Door switch ground condition (Except driver side) ● Harness for open or short between control unit and door switch

EL-292

NG

왘

Replace door switch.

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 — With driver door switch type-2 — (Door switch check) Fuse block (J/B) connector

CHECK DOOR SWITCH INPUT SIGNAL. Check voltage between fuse block (J/B) and ground. Terminals

YEL450B

Driver side door Other door

Condition

Voltage [V]

Opened

0

OK

왘

Door switch is OK.

16J

Closed

Approx. 12

Opened

0

Closed

Approx. 12

7J

NG 왔

YEL033D

CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗

Condition

Continuity

Closed

No

Open

Yes

OK 왔

Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch

EL-293

NG

왘

Replace door switch.

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 (NATS release signal check) Time control unit connector

NATS IMMU

No

Does engine start properly?

왘

Check NATS system.

Yes 왔

YEL451B

Time control unit connector

CHECK NATS SIGNAL CIRCUIT. 1) Disconnect control unit connector and NATS IMMU connector. 2) Check continuity between control unit terminal 쑗 26 and NATS IMMU terminal 쑗 3 . Continuity should exist. 3) Check continuity between control unit terminal 쑗 26 and ground. Continuity should not exist.

NG

왘

Repair harness.

OK 왔

CHECK NATS RELEASE SIGNAL. 1) Connect control unit connector and NATS IMMU connector. 2) Check voltage between control unit terminal 쑗 26 and ground. Ignition switch condition

Voltage [V]

LOCK More than 10 seconds after ignition switch turned to “ON” position YEL452B

For 10 seconds after ignition switch turned to “ON” position

OK 왔

Replace super lock control unit.

EL-294

12

Pulse

NG

왘

Check NATS system.

POWER DOOR LOCK — Super Lock — Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 (Key switch check) Time control unit connector

CHECK IGNITION KEY SWITCH INPUT SIGNAL. Check voltage between control unit terminal 쑗 22 and ground. Condition of key switch

Voltage [V]

Key is inserted

Approx. 12

Key withdrawn

0

YEL453B

OK

왘

Key switch is OK.

NG 왔

Key switch connector

CHECK KEY SWITCH POWER SUPPLY. Check voltage between key switch harness terminal 쑗 2 and ground. Battery voltage should exist.

왘

OK

YEL826 왔

NG

CHECK KEY SWITCH. 1) Disconnect key switch connector. 2) Check continuity between key switch terminals.

Key switch connector

NG

Terminals

쑗 1

-쑗 2

YEL827

Condition

Continuity

Key is inserted.

Yes

Key is withdrawn.

No

왘

Check the following. ● 10A fuse [No. 16 , located in fuse block (J/B)] ● Harness for open or short between key switch and fuse

Replace key switch.

OK 왔

Check harness for open or short between control unit and key switch.

DIAGNOSTIC PROCEDURE 8 (Ignition switch “ON” circuit check) Terminals Time control unit connector

䊝 1 쑗

Ignition switch position 䊞

OFF

ACC

ON

Ground

0V

0V

Battery voltage

If NG, check the following. ● 10A fuse [No. 26 , located in the fuse block (J/B)] ● Harness for open or short YEL454B

EL-295

MULTI-REMOTE CONTROL SYSTEM System Description The multi-remote control system controls operation of the ● power door lock (and super lock)

OPERATED PROCEDURE Power door lock operation When the following input signals are both supplied: ● Key switch OFF (when ignition key is not inserted in key cylinder); ● door switch CLOSED (when all the doors are closed); The two above signals are already input into time control unit. At this point, time control unit receives a LOCK signal from remote controller. Time control unit locks all doors and set super lock with input of LOCK signal from remote controller. When an UNLOCK signal is sent from remote controller once, driver’s door will be unlocked and release super lock. Then, if an UNLOCK signal is sent from remote controller again, all other door will be unlocked.

Multi-remote controller ID code entry For detailed procedure, refer to “ID Code Entry Procedure” in EL-305.

EL-296

MULTI-REMOTE CONTROL SYSTEM Schematic

IGNITION SWITCH On or START

FUSE

BATTERY

BATTERY (Via fusible link)

FUSE

FUSIBLE LINK

KEY SWITCH

CIRCUIT BREAKER-1

To door lock actuators

TIME CONTROL UNIT

DOOR LOCK ACTUATOR ASSEMBLY (REAR LH)

DOOR LOCK ACTUATOR ASSEMBLY (DRIVER’S SIDE) UNLOCK

LOCK

UNLOCK SENSOR

FRONT DOOR SWITCH (DRIVER’S SIDE)

FRONT DOOR SWITCH (PASSENGER SIDE)

REAR DOOR SWITCH LH

LOCK

UNLOCK SENSOR

DOOR LOCK ACTUATOR ASSEMBLY (REAR RH)

DOOR LOCK ACTUATOR ASSEMBLY (PASSENGER SIDE) UNLOCK

UNLOCK LOCK

UNLOCK SENSOR

UNLOCK

LOCK

UNLOCK SENSOR

TRUNK OR LUGGAGE ROOM LAMP SWITCH

REAR DOOR SWITCH RH

YEL206C

EL-297

MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — IGNITION SWITCH ON or START

BATTERY

Refer to EL-POWER

FUSE BLOCK (J/B)

CIRCUIT BREAKER-1

TIME CONTROL UNIT

INSERTED

KEY SWITCH

WITHDRAWN

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

: This connector is not shown in “HARNESS LAYOUT” of EL section.

YEL207C

EL-298

MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d)

YEL920C

EL-299

MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d)

YEL921C

EL-300

MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d) MODELS WITHOUT SUPER LOCK

YEL922C

EL-301

MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — (Cont’d) MODELS WITH SUPER LOCK

YEL923C

EL-302

MULTI-REMOTE CONTROL SYSTEM Trouble Diagnoses If no doors can not be unlocked by remote controller operation then the following procedure is required. A) Unlock the vehicle by a mechanical key in the drivers door key cylinder. Note: this may cause the alarm to sound. B) Put the key in ignition, turn to ON position for at least five seconds. Assuming the ignition key contains a valid transponder then a signal will be generated by the immobilizer which will disarm the alarm and allow key learn mode to be entered. C) Turn ignition OFF and wait for ten seconds.

SYMPTOM CHART Symptom No doors can be locked or unlocked by remote control operation.

Possible cause 1. Remote controller battery 2. Power door lock system 3. Key switch (insert) 4. Door switch 5. Power supply circuit for time control unit 6. Ground circuit for time control unit 7. Remote controller

The new ID of remote controller cannot be entered.

1. Remote controller battery 2. Key switch (insert) 3. Door switch 4. Driver’s door unlock sensor 5. Ignition ON power supply circuit for time control unit 6. Remote controller

Diagnoses/service order 1. Check remote controller battery. Refer to EL-304. 2. Check that power door lock operates properly. If NG, check power door lock. 3. Check key switch (insert) signal at terminal 쑗 22 of time control unit. 4. Check door switch signal at terminals 쑗 6 and 7 of time control unit. 쑗 5. Make sure battery voltage is present at terminal 9 of time control unit. 쑗 6. Check continuity between terminal 쑗 16 of time control unit and ground. 7. Replace remote controller. Refer to EL-305. 1. Check remote controller battery. Refer to EL-304. 29 2. Check key switch (insert) signal at terminal 쑗 of time control unit. 3. Check door switch signal at terminals 쑗 6 and 7 of time control unit. 쑗 4. Check driver’s door unlock sensor signal at terminal 쑗 35 of time control unit. 5. Make sure battery voltage is present at terminal 1 of time control unit while ignition switch is in 쑗 ON position. 6. Replace remote controller. Refer to EL-305.

Refer to “TIME CONTROL UNIT INSPECTION TABLE” on next page to check the control unit signals. NOTE: ● The unlock operation of multi-remote control system does not activate with key inserted in the ignition key cylinder. ● The lock operation of multi-remote controller does not activate with the key inserted ignition key cylinder or if one of the door is opened.

EL-303

MULTI-REMOTE CONTROL SYSTEM Trouble Diagnoses (Cont’d) TIME CONTROL UNIT INSPECTION TABLE Voltage (V) (approximate values)

Terminal No.

Wire color

1

—

Ignition switch (ON)

Ignition key “ON” position

5

—

Driver door switch

OFF (Closed) , ON (Open)

12V , 0V

7

—

All door switches

OFF (Closed) , ON (Open)

12V , 0V

8

—

Power source (C/B)

—

12V

9

—

Power source (Fuse)

—

12V

16

—

Ground

22

Connections

Operated condition

12V

—

Ignition key switch BR/W (Insert)

12V

Key inserted , key removed from IGNB key cylinder

0V , 12V

Rear door unlock sensors

Rear doors: Locked , Unlocked

12V , 0V

Trunk or luggage room lamp switches

OFF (Closed) , ON (Open)

12V , 0V

25

Y/G

33

R

35

Y/R

Driver door unlock sensor

Driver door: Locked , Unlocked

12V , 0V

36

Y/L

Passenger door unlock sensor

Passenger door: Locked , Unlocked

12V , 0V

REMOTE CONTROLLER BATTERY CHECK Remove battery and measure voltage across battery positive and negative terminals, 䊝 and 䊞. Measuring terminal

Stamped (+) SEL672U

䊝

䊞

Standard value

Battery positive terminal 䊝

Battery negative terminal 䊞

2.5 - 3.0V

Note: Remote controller does not function if battery is not set correctly.

EL-304

MULTI-REMOTE CONTROL SYSTEM ID Code Entry Procedure Activation of the registration mode: The vehicle must have been unlocked by either the multi-remote controller or a transponder OK signal (TPOK) from the vehicle’s immobilizer. Preparation: - Make sure all doors unlock. - Make sure all multi-remote controllers to be registered are available. - Make sure the batteries of all multi-remote controllers are in a good condition. - Make sure all transmitting sources are out of the neighbourhood of the vehicle . - Make sure the battery of the vehicle is in a good condition.

왗

왔

Switch ignition-switch exactly six times from the “LOCK” to the “ON” position within 10 seconds and return the ignition switch to the “LOCK” position (leaving the key in the ignition switch).

왗

왔

NG

After 2 seconds the registration mode is activated. The turn signal lamps will flash twice. OK 왔

Proceed with the registration mode. NOTE The registration mode is operated when: ● The ignition-switch is turned to the “ON” position. ● 4 multi remote controllers have been learned. ● No multi-remote controller or ignition switch input is received within 120 seconds.

Registration mode 왔

Press and hold the “UNLOCK” button of the multi-remote controller.

왗

왔

Press the “LOCK” button 3 times. NEL569 왔

Release the “UNLOCK” button.

If the multi-remote controller code is registered correctly, the turn signal lamp will OK flash once. 왘

왔

Do you want to register another multi-remote controller? (max. 4) No

왗

Yes

왔

After registration of the requested No. of multi-remote controller(s), confirm the ID-code(s) by switching the ignition switch to the “ON” position.

Take the ignition key out of the ignition switch and confirm the functioning of all multi-remote controllers by locking and unlocking the vehicle with each of the multi-remote controllers. 왔

End

EL-305

왘

If the multi-remote controller registration is performed correctly, the turn signal lamp will flash twice.

왗

OK

NG

NG

왘 왖

TIME CONTROL UNIT (TCU) System Description The TCU has the following functions.

INTERIOR LAMP TIMER The interior lamp timer is controlled by the TCU. For further information, refer to “INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS” (EL-130).

IGNITION KEY WARNING CHIME AND LIGHT WARNING CHIME The ignition key and light warning chime are controlled by the TCU. For further information, refer to “WARNING CHIME” (EL-180).

REAR WINDOW DEFOGGER TIMER Ther rear window defogger and door mirror defogger system are controlled by the TCU. For further information, refer to “REAR WINDOW DEFOGGER AND DOOR MIRROR DEFOGGER” (EL-207).

POWER DOOR LOCK (Super Lock) The power door lock (super lock) is controlled by the TCU. For further information, refer to “POWER DOOR LOCK — Super Lock” (EL-265).

MULTI-REMOTE CONTROL SYSTEM The multi-remote control system is controlled by the TCU. For further information, refer to “MULTI-REMOTE CONTROL SYSTEM” (EL-296).

THEFT WARNING SYSTEM The theft warning system is controlled by the TCU. For further information, refer to “THEFT WARNING SYSTEM” (EL-311).

EL-306

TIME CONTROL UNIT (TCU) System Description (Cont’d) FUNCTION ●

The TCU has the following control functions.

Item

Details of control

Direction indicators

Switches the director indicators (Left, Right or All) when the combination switch or hazard switch is operated.

Trailer direction indicator buzzer

Sounds a buzzer during direction indicator operation when towing a trailer.

Light warning buzzer

Sounds warning buzzer when driver’s door is opened with light switch in the 1st or 2nd position and ignition switch “OFF”.

Ignition key warning buzzer

Sounds warning buzzer when driver’s door is opened with key in ignition and the driver door lock knob is moved from the “unlock” position to the “lock” position.

Rear window defogger timer

Turn off rear window defogger and door mirror heater, if equipped, about 15 minutes after the rear window defogger switch is turned “ON”.

Battery saver

Shuts off interior lamp in 30 minutes if any door is left open when ignition switch is “OFF”. The battery saver will reset if ignition switch is cycled or any door is opened or closed.

Interior lamp timer

Keep interior lamp illuminated for about 30 seconds when: driver’s door is unlocked, ● the ignition is switched off, ● driver’s door is opened and then closed. The timer is cancelled, and interior lamp turns off when: ● driver’s door is locked, or ● ignition switch is turned “ON”. ●

Theft warning system

Normal operation

Monitors doors, hood, boot lid, door locks, volumetric sensors (if not excluded), ignition and glass break sensors (wagon) when armed. Flashes the direction indicators and sounds the horn for 30 seconds in case one of the monitored sensors is triggered.

Diagnostic mode

Indicates the last three alarm triggers by flashing the direction indicators.

Central door lock

Centrally locks and unlocks the vehicle

Super lock

Activates and de-activates the super lock system.

EL-307

TIME CONTROL UNIT (TCU) System Description (Cont’d) REAR WINDOW DEFOGGER TIMER The rear window defogger and door mirror defogger system are controlled by the TCU. With the ignition switch in the ON or START position, power is supplied ● to the rear window defogger relay ● to TCU terminal 쑗 1 ● through 10A fuses [No. 5 , located in the fuse block (J/B)]. Ground is supplied to terminal 쑗 14 of the rear window defogger switch through body grounds M6 , M26 and M28 . When the rear window defogger switch is ON, ground is supplied ● through terminal 쑗 16 of the rear window defogger switch ● to TCU terminal 쑗 3 . 13 of the TCU then supplies ground to the rear window defogger relay. Terminal 쑗 With power and ground supplied, the rear window defogger relay is energized to operate rear window defogger and door mirror defogger for about 15 minutes. For further information, refer to REAR WINDOW DEFOGGER DOOR and MIRROR DEFOGGER (EL-207).

IGNITION KEY WARNING BUZZER Ground is supplied to TCU terminal 쑗 6 through front driver’s side door switch when switch is in OPEN position from body ground. With the key in the ignition switch in the ACC or OFF position, and locking the driver’s door from the inside, the warning buzzer will sound.

LIGHT WARNING BUZZER Power is supplied at all times ● through 30A fusible link (letter g , located in the fuse and fusible link box) (LHD models) ● through 15A fuse (No. 66 , located in the fuse and fusible link box) (RHD models) ● to lighting switch terminal 쑗 11 . Power is supplied at all times ● through 7.5A fuse [No. 40 , located in the fuse block (J/B)] ● to warning buzzer terminal 쑗 1 . With the ignition switch in the ON or START position, power is supplied ● through 7.5A fuse [No. 12 , located in the fuse block (J/B)] ● to BCM terminal 쑗 29 . Ground is supplied to TCU terminal 쑗 6 through front driver’s side door switch when switch is in OPEN position from body ground. With the ignition switch in the ACC or OFF position, the driver’s door OPEN, and the lighting switch in the 1st or 2nd position, the warning buzzer will sound.

INTERIOR LAMP TIMER Power is supplied at all times ● through 10A fuse [No. 5 , located in the fuse block (J/B)] ● to interior lamp terminal 쑗 1 With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 26 , located in the fuse block (J/B)] ● to TCU terminal 쑗 1 . When the driver’s door is unlocked, a door is opened and then closed, or the ignition is turned from “ON” 2 for approximately 30 seconds. to “Acc” or “LOCK”, ground is supplied to the interior lamp terminal 쑗 The 30 seconds timer will be cancelled if the ignition switch is turned to “ON”, or the driver’s door is locked.

EL-308

TIME CONTROL UNIT (TCU) Trouble Diagnosis The Timer Control Unit includes software to help during development testing, manufacturing and service. It allows the technician to put it into Diagnostic Mode. In this mode, all switch inputs can be tested for continuity and if so equipped, alarm triggers identified. When the time control unit is in Diagnostic Mode, the control unit tests the component and indicate the result by the hazard lamp flashing. On vehicles with a theft warning system, the TCU will first indicate the source of the last three alarm triggers by flashing the hazard lamp. (Refer to “THEFT WARNING SYSTEM”, EL-311.)

왘

START NOTE: Before entering diagnostic mode, make sure the vehicle is fully unlocked, the ignition is switched off and the hazard switch is off.

왔

Press the rear defogger switch exactly 6 times within 10 seconds.

NG 왗

왔

The hazard lamp flash at 3Hz for 1 second to confirm step I. OK 왔

Within 10 seconds after confirmation of step I, turn the ignition ON, for at least 2 seconds.

NG 왗

왔

The hazard lamp flash at 3Hz for 1 second to confirm step II. OK 왔

Within 10 seconds after confirmation of step II, turn the ignition off, remove the ignition key and press the rear defogger switch for at least 5 seconds.

NG

왔

The hazard lamp flash at 3Hz for 3 seconds to confirm diagnostic mode is entered.

EL-309

TIME CONTROL UNIT (TCU) Trouble Diagnosis (Cont’d) Checks Once in Diagnostic Mode (and after identifying the last three alarm triggers in case a theft warning system is equipped on the vehicle), the following inputs can be tested. USER ACTION

TCU Reaction

COMPONENT TESTED

Driver’s door opened from closed (all other doors closed)

Hazards flash once

Driver’s door open signal

Passenger or rear door opened from closed (all other doors closed)

Hazards flash once

Door open signal for opened door

Driver’s door locked from unlocked

Hazards flash once

Driver’s door status signal

Passenger door locked from unlocked

Hazards flash once

Assist door status signal

Rear doors locked from unlocked (with ultrasonic model)

Hazards flash once

Rear doors status signal

Ultrasonics cancel switch is pressed (with ultrasonic model)

Hazards flash once

U/S cancel signal

Trunk or back door is opened from closed

Hazards flash once

Trunk open signal

Hood is opened from closed (with ultrasonic model)

Hazards flash once

Hood open signal

Hazard switch is pressed from off

Hazards flash once

Hazard switch signal

Turn signal switch is moved to left from off

Hazards flash once

Left turn signal

Turn signal switch is moved to right from off

Hazards flash once

Right turn signal

Key turned to lock position in door

Hazards flash once *

Key cylinder lock switch signal

Lighting switch turned 1st position or 2nd position from off

Hazards flash once

Tail lamp signal

Key put in ignition from out

Hazards flash once

Key in detect signal

Central unlock/Trunk release switch is pressed

Hazards flash once

Central unlock/Trunk release signal

External trunk release switch pressed from off

Hazards flash once

External trunk release switch signal

*) Hazards may flash a second time because of Driver’s door status signal change. The min. delay time between flash actions is 100ms.

In case the system does not operate as described above, check the concerned circuit for open or short. After completion, the Diagnostic Mode can be switched off by pressing the rear defogger switch or by turning the ignition to “ON”. The hazard lamp will flash at 3Hz for 3 seconds to confirm that Diagnostic Mode has been switched off.

EL-310

THEFT WARNING SYSTEM Components Parts and Harness Connector Location Rear door switch RH

Door unlock sensor RH

Trunk room/Luggange room lamp switch

Ultrasonic sub sensor

Ultra sonic sensor Door unlock sensor

Theft warning horn

Front door switch RH

Security indicator light

Rear door switch

Door unlock sensor LH

Ultrasonic cancel switch

Door key cylinder switch Door unlock sensor Front door switch LH

Time control unit Hood switch Theft warning horn relay

Time control unit Hood switch

Theft warning horn

.

.

Trunk room/luggage room lamp switch

Door key cylinder switch

Door unlock sensor Ultrasonic sensor

Ultrasonic cancel switch

Ultrasonic sub sensor

NEL529

EL-311

THEFT WARNING SYSTEM System Description OPERATION FLOW The SECURITY indicator can be operated by both the IMMU (for NATS) and the TCU (for Theft Warning). The flow chart shows both operations. SYSTEM phase

Theft warning (TCU)

NATS (IMMU)

Ignition “ON” Disarmed

Ignition “ACC” or “LOCK” Disarmed

T1 (0.2 sec) T2 (2.4 sec)

Ignition “ACC” or “LOCK” Pressing Ultrasonic Cancel Switch

T3 (6 sec)

T4 (30 sec) Ignition “LOCK” Pre-armed (4/5DR)

f=8Mhz

T4 (30 sec) Ignition “LOCK” Pre-armed (Wagon)

T5 (1 sec) Ignition “LOCK” Armed

Ignition “LOCK” Disarmed

NEL568

EL-312

THEFT WARNING SYSTEM System Description (Cont’d) SETTING THE THEFT WARNING SYSTEM Initial condition (1) Close all doors. (2) Close hood and trunk lid.

Pre-armed phase and armed phase The theft warning system turns into the “pre-armed” phase when hood, trunk lid and all doors are closed and locked by key or multi-remote controller. (The security indicator lamp blinks intermittently for 30 seconds.) After about 30 seconds, the system automatically shifts into the “armed” phase (the system is set).

CANCELING THE SET THEFT WARNING SYSTEM When the following (a) or (b) operation is performed, the armed phase is canceled. (a) Unlock the doors with the multi-remote controller. (b) Insert key in ignition key cylinder and turn it to ON. Then NATS IMMU will send a disarm signal to the time control unit.

ACTIVATING THE ALARM OPERATION OF THE THEFT WARNING SYSTEM Make sure the system is in the armed phase. When the following operation (a) (b) (c) (d) or (e)is performed, the system sounds the horns and flashes the hazard lamp for about 30 seconds. (a) Engine hood, trunk lid or any doors is opened before unlocking door with the multi-remote controller. (b) A door is unlocked without using the multi-remote controller. (c) The ignition is switched ON without using a NATS registered key. (d) The ultra sonic sensing is triggered. (e) A rear side or rear screen breakage is detected (Wagon).

POWER SUPPLY AND GROUND CIRCUIT Power is supplied at all times. ● Through 10A fuse [No. 16 , located in the fuse block (J/B)] ● to security indicator lamp terminal 쑗 2 . Power is supplied at all times ● through 10A fuse [No. 5 , located in the fuse block (J/B)] ● to time control unit terminal 쑗 9 . With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 26 , located in the fuse block (J/B)] ● to time control unit terminal 쑗 1 . Ground is supplied ● to time control unit terminal 쑗 16 . ● through body grounds M6 , M28 and M26 .

INITIAL CONDITION TO ARM THE SYSTEM The operation of the theft warning system is controlled by all the doors, hood and trunk lid. To activate the theft warning system, the time control unit must receive signals indicating all the doors, hood and trunk lid are closed and the doors are locked. 6 or 쑗 7 receives a ground signal from each door switch. When a door is open, time control unit terminal 쑗 When a door is unlocked, time control unit terminal 쑗 25 , 쑗 35 or 쑗 36 receives a ground signal from terminal 5 of each door unlock sensor. 쑗 When the hood is open, time control unit terminal 쑗 32 receives a ground signal ● from terminal 쑗 1 of the hood switch ● through body grounds E11 and E37 . When the trunk lid is open, time control unit terminal 쑗 33 receives a ground signal ● from terminal 쑗 1 of the trunk room lamp switch ● through body grounds B18 and B27 . 33 receives a ground signal When the back door, trunk or tail gate is open, time control unit terminal 쑗 ● from terminal 쑗 1 of the luggage room lamp switch ● through body grounds B48 and D110 .

EL-313

THEFT WARNING SYSTEM System Description (Cont’d) THEFT WARNING SYSTEM ARMING (With key or remote controller used to lock doors) If the key is used to lock doors, time control unit terminal 쑗 29 receives a ground signal ● from terminal 쑗 2 of the key cylinder switch ● through body grounds B18 and B27 . If this signal or lock signal from remote controller is received by the time control unit, the theft warning system will arm automatically. When arming the theft warning system, time control unit terminal 쑗 18 supplies ground intermittently to ter1 of the security indicator lamp. The security lamp will blink intermittently for approximately 30 secminal 쑗 onds (and then blink every 2.6 seconds, due to NATS). Now the theft warning system is in armed phase.

THEFT WARNING SYSTEM ALARM OPERATION The theft warning system is triggered by ● opening a door ● opening the trunk lid or back door ● opening the hood ● unlocking door without using the multi-remote controller ● switching the ignition ON without a NATS registered key ● triggering the ultra sonic sensors ● smashing the back door or rear side quarter window (wagon model only). Once the theft warning system is in armed phase, if the time control unit receives a signal at terminal 쑗 25 , 35 , 36 (door unlock sensor), 6 , 7 (door switch), 33 (trunk room lamp switch or luggage room lamp 쑗 쑗 쑗 쑗 쑗 switch), 쑗 32 (hood switch),쑗 31 (smash sensor) or 쑗 17 (ultra sonic sensor) the theft warning system will be triggered. The hazard lamps flash and the horn sounds intermittently. Power is supplied at all times ● through 10A fuse [No. 16 , located in the fuse block (J/B)]. ● to theft warning relay terminal 쑗 2 . If the theft warning system is triggered, ground is supplied ● from terminal 쑗 43 of the time control unit ● to theft warning relay terminal 쑗 1 . The hazard lamps flash and the horn sounds intermittently. The alarm automatically turns off after 30 seconds but will reactivate if the vehicle is tampered with again, or if the initial cause remains present.

THEFT WARNING SYSTEM ALARM DISARMING The theft warning system alarm operation can be deactivated by either unlocking the vehicle with the remote controller, or turning the ignition to the “ON” position with a registered NATS key.

SMASH SENSOR The smash sensor will trigger the alarm when the rear side or rear screen is broken. There are three windshield protected: 1. Back door window. Sensor circuit is bonded to the glass. 2. Rear side quarter windows (one each side). Sensor circuit is bonded to the glass. All three sensor are wired in series. By breaking any of the three windshields (sensor circuit open), the alarm will sound.

EL-314

THEFT WARNING SYSTEM Schematic

YEL924C

EL-315

THEFT WARNING SYSTEM Wiring Diagram — THEFT —

YEL925C

EL-316

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)

EL-THEFT-02 TIME CONTROL UNIT

B12 32

21

17

20

Y/B

P

PU

B/Y

P

PU

B/Y

7

2

8

Y/B B57

ULTRASONIC SENSOR

E115

B29

9 Y/B

6

5

4

3

Y

L

SB

G

Y/B

P

Y

L

SB

G

B/Y

1

5

4

3

2

1

6 ULTRASONIC SUB SENSOR

HOOD SWITCH

OPEN

B15

E12 CLOSED

2 B

1 2

E12 GY

B

B

E11

E37

1 2 3 4 5 6

1 2 3 4 5 6 7 8

B29 W

B15 W

1 2 3 4 5 6 7 B57 8 9 10 11 12 13 14 15 16 W

24 23 22 21 20 19 18 17 B12 36 35 34 33 32 31 30 29 28 27 26 25 W

YEL358B

EL-317

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)

YEL927C

EL-318

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750 TIME CONTROL UNIT

To EL-THEFT-01

: 4 door models : 5 door hatchback models THEFT WARNING HORN RELAY

OPEN CLOSED

TRUNK ROOM LAMP SWITCH

OPEN

: 5 door hatchback models and wagon models : Wagon models

LUGGAGE ROOM LAMP SWITCH

CLOSED

THEFT WARNING HORN

YEL213C

EL-319

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750

YEL928C

EL-320

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models before VIN - P11U0548750

YEL929C

EL-321

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750

YEL930C

EL-322

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750

YEL931C

EL-323

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d) Models after VIN - P11U0548750

YEL932C

EL-324

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)

YEL933C

EL-325

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)

YEL934C

EL-326

THEFT WARNING SYSTEM Wiring Diagram — THEFT — (Cont’d)

YEL935C

EL-327

THEFT WARNING SYSTEM Trouble Diagnoses Alarm Trigger Feedback To verify the last three triggers that activated the theft warning system, the Time Control Unit (TCU) can be switched into Diagnostic Mode (see page EL-309 how to enter Diagnostic Mode). Approximately 2 seconds after the TCU has finished flashing the hazard lamp to confirm that the Diagnostic Mode has been successfully entered, the TCU will generate a short beep indicating the trigger that will be displayed. A single beep means the most recent trigger, three beeps means the oldest trigger. Following each beep or group of beeps, the hazard lamp will flash to indicate the alarm trigger. Source of Alarm Trigger

Number (of flashes)

Driver’s door lock status switch

1

Passenger door lock status switch

2

Rear door lock status switch

3

Ignition line

4

Driver’s door open switch

5

Other door open switch

6

Trunk or back door open switch

8

Hood switch

9

Ultra sonic sensors

10

Smash sensor (Wagon vehicles)

11

In case there have been no alarm triggers, there will be no indicator flashes between the audible signals. After completing the alarm trigger feedback, the TCU will enter Diagnostic Mode as described on page EL-309. Before continuing trouble diagnoses on the next page, perform the checks as mentioned in the table on page EL-310.

EL-328

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) PRELIMINARY CHECK The system operation is canceled by turning the ignition switch to “ON” at any step between START and ARMED in the following flow chart. System phase

왘DISARMED

START Note: Before starting operation check, open front windows. 왔

Turn ignition switch “OFF” and remove the ignition key. “SECURITY” indicator lamp will blink every 2.6 seconds. (NATS)

NG

Refer to NATS trouble diagnosis.

NG

SYMPTOM 1

NG

SYMPTOM 2

왘

OK 왔

Close all doors, hood and trunk lid. 왔

Press the ultrasonic cancel switch. The “SECURITY” indicator lamp will go on for approximately 6 seconds. OK

왔

PRE-ARMED

왔

Lock doors using key or multi-remote controller.

왔

ARMED

왘

왔

For about 30 seconds, “SECURITY” indicator lamp will blink intermittently.

왘

OK 왔

Disarm the system by unlocking the vehicle using the remote controller. Arm the system again without excluding the ultrasonic sensors. 왔

ALARM

왔

NG SYMPTOM 3 Unlock any door without multi-remote controller, activate the 왘 ultra sonic sensors by inserting an object into the vehicle’s interior, or open hood or trunk. ....................................................................................................... NG SYMPTOM 4 Alarm (horn and hazard lamp) will operate. 왘 OK

왔 왘DISARMED

왔

Unlock the vehicle using the multi-remote controller or insert the key in the ignition and switch it to ON. Alarm (horn and hazard lamp) will stop. OK 왔

System is OK.

After performing preliminary check, go to symptom chart on next page.

EL-329

NG

왘

SYMPTOM 5

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) Before starting trouble diagnoses below, perform preliminary check, EL-329. Symptom numbers in the symptom chart correspond with those of Preliminary check.

SYMPTOM CHART

EL-331

EL-331

EL-332

EL-336

EL-337

EL-338

EL-339

EL-340

EL-341

EL-296

EL-342

Power supply circuit check

Ground circuit check

Diagnostic Procedure 1 (Door, hood and trunk room lamp switch check)

Diagnostic Procedure 2 (Security indicator lamp check)

Diagnostic Procedure 3 (Door unlock sensor check)

Diagnostic Procedure 4 (Door key cylinder switch check)

Diagnostic Procedures 5 (Smash sensor check)

Diagnostic Procedure 6 (Theft warning horn alarm check)

Diagnostic procedure 7 (Hazard lamp alarm check)

Check “MULTI-REMOTE CONTROL” system.

Check “NATS (Nissan Anti-Theft system)”.

5

Theft warning system cannot be set by... *1 Theft warning system does not alarm when... Theft warning alarm does not activate.

4

—

X

All items

X

X

X

Door out side key

X

X

X

Multi-remote control

X

X

X

Any door is opened.

X

X

X

Any door is unlocked without using key or multi-remote controller

X

X

X

Glass breakage is deteted (Wagon)

X

X

X

All function

X

X

X

Horn alarm

X

X

X

Hazard lamp

X

X

X

Turning the ignition ON *2

X

X

X

Multi-remote controller

X

X

X

Security indicator does not turn “ON” or blinking.

Theft warning system cannot be canceled by...

3

—

X

SYMPTOM

2

Diagnostic procedure

X

REFERENCE PAGE

1

Power supply and ground circuit check

EL-329

—

Preliminary check

Procedure

X X

X X X

X X

X X

X: Applicable *1: Make sure the system is in the armed phase. *2: Make sure the key is NATS registered.

EL-330

X X X

X

X

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK Main power supply circuit check Time control unit connector

Terminals 䊝

Ignition switch position 䊞

OFF

ACC

ON

9 쑗

Ground

Battery voltage

Battery voltage

Battery voltage

1 쑗

Ground

0V

0V

Battery voltage

YEL430B

Ground circuit check Time control unit connector

Terminals 16 쑗

- Ground

YEL431B

EL-331

Continuity Yes

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(1) — With driver door switch type-1 — (Door switch check) Fuse block (J/B) connector

YEL829

CHECK DOOR SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between fuse block (J/B) and ground. Terminals

Door switch connector Driver side:

Driver side door Other door

Condition

Continuity

Opened

Yes

OK

왘

Door switch is OK.

16J

Closed

No

Opened

Yes

Closed

No

7J

YEL831

NG 왔

CHECK GROUND CIRCUIT. 1) Disconnect driver side door switch connector. 2) Check harness continuity between terminal 쑗 2 and ground. Continuity should exist.

Door switch connector Driver side:

NG

왘

Repair harness or connector.

OK 왔

CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Door switch connector Passenger side:

Terminals Condition

Rear side:

Driver side door switch

YEL830

Other door switches

2 -쑗 3 쑗 1 쑗

ground

Continuity

Closed

No

Open

Yes

Closed

No

Open

Yes

OK 왔

Check the following. ● Door switch ground condition (Except driver side) ● Harness for open or short between control unit and door switch

EL-332

NG

왘

Replace door switch.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(1) — With driver door switch type-2 — (Door switch check) Fuse block (J/B) connector

YEL829

CHECK DOOR SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between fuse block (J/B) and ground. Terminals Driver side door Other door

Condition

Continuity

Opened

Yes

OK

왘

Door switch is OK.

16J

Closed

No

Opened

Yes

Closed

No

7J

YEL033D

NG 왔

CHECK DOOR SWITCH. 1) Disconnect door switch connector. 2) Check continuity between door switch terminals. Terminals 1 - ground 쑗

Condition

Continuity

Closed

No

Open

Yes

OK 왔

Check the following. ● Door switch ground condition ● Harness for open or short between control unit and door switch

EL-333

NG

왘

Replace door switch.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(2) (Hood switch check) Time control unit connector

YEL457B

Hood switch connector

CHECK HOOD SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminal 쑗 32 and ground. Condition

Continuity

Hood is open.

Yes

Hood is closed.

No

OK

왘

Hood switch is OK.

Refer to wiring diagram in EL-317. OK 왔 YEL458B

CHECK HOOD SWITCH. 1. Disconnect hood switch connector. 2. Check continuity between hood switch terminals. Terminals 1 -쑗 2 쑗

Condition

Continuity

Pushed

No

Released

Yes

OK 왔

Check the following. ● Hood switch ground circuit ● Harness for open or short between control unit and hood switch

EL-334

NG

왘

Replace hood switch.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1-(3) (Trunk room or luggage room lamp switch check) Time control unit connector

YEL459B

Trunk room lamp switch connector Luggage room lamp switch

CHECK TRUNK ROOM OR LUGGAGE ROOM LAMP SWITCH INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminal 쑗 33 and ground. Condition

Continuity

Trunk lid or back door is open.

Yes

Trunk lid or back door is closed.

No

OK

왘

Trunk room or luggage room lamp switch is OK.

Refer to wiring diagram in EL-319. NG 왔

CHECK TRUNK ROOM OR LUGGAGE ROOM LAMP SWITCH. 1. Disconnect trunk room or luggage room lamp switch connector. 2. Check continuity between trunk room lamp switch terminals.

Luggage room lamp switch

Terminals

YEL460B

1 -쑗 2 쑗

Condition

Continuity

Closed

No

Open

Yes

OK 왔

Check the following. ● Trunk room or luggage room lamp switch ground circuit ● Harness for open or short between control unit and trunk room or luggage room lamp switch

EL-335

NG

왘

Replace trunk room or luggage room lamp switch.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (Security indicator check) Time control unit connector

YEL461B

CHECK INDICATOR LAMP OUTPUT SIGNAL. 1) Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2) Check voltage between control unit terminal 쑗 18 and ground. Battery voltage should exist. Refer to wiring diagram EL-316.

Security indicator connector

OK

왘

Security indicator lamp is OK.

NG Security indicator on dashboard

Security indicator built-in combination meter 왔

CHECK INDICATOR LAMP.

NG

YEL462B

왘

왘

A 쑗

Replace indicator lamp.

OK 왔

CHECK POWER SUPPLY CIRCUIT FOR INDICATOR. 1) Disconnect security indicator connector. 2) Check voltage between indicator terminal 쑗 2 and ground. Battery voltage should exist.

NG

왘

OK

Check the following: 10A fuse [No. 16 , located in the fuse block (J/B)] ● Harness for open or short between security indicator lamp and fuse ●

왔

Check harness for open or short between security indicator and control unit.

A 쑗

왔

CHECK INDICATOR LAMP.

NG

왘

Replace combination meter.

왘

Check the following: 10A fuse [No. 16 , located in the fuse block (J/B)] ● Harness for open or short between combination meter and fuse

OK 왔

YEL037D

CHECK POWER SUPPLY CIRCUIT FOR INDICATOR. 1) Disconnect combination meter connector. 2) Check voltage between indicator terminal 쑗 23 and ground. Battery voltage should exist. 왔

OK

Check harness for open or short between combination meter and control unit.

EL-336

NG

●

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 (Door unlock sensor check) Time control unit connector

YEL463B

CHECK DOOR UNLOCK SENSOR INPUT SIGNAL. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between control unit terminals 쑗 25 , 쑗 35 , 쑗 36 and ground.

OK

왘

Door unlock sensor is OK.

왘

Replace door unlock sensor.

Terminals 䊝

䊞

Driver side door

35 쑗

Ground

Passenger side door

36 쑗

Ground

Rear door

25 쑗

Ground

YEL038D

Condition

Continuity

Locked

No

Unlocked

Yes

Locked

No

Unlocked

Yes

Locked

No

Unlocked

Yes

Refer to wiring diagram in EL-327. NG 왔

CHECK DOOR UNLOCK SENSOR. 1. Disconnect door unlock sensor connector. 2. Check continuity between door unlock sensor terminals. Terminals 2 -쑗 5 쑗

Condition

Continuity

Locked

No

Unlocked

Yes

OK 왔

Check the following: ● Door unlock sensor ground circuit ● Harness for open or short between control unit and door unlock sensor

EL-337

NG

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 (Door key cylinder switch check)

Time control unit connector

CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK SIGNAL). Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. Check continuity between time control unit connector terminal 쑗 29 and ground.

Continuity exists Neutral Unlock Lock

LH side Neutral Unlock

OK

왘

Door key cylinder switch is OK.

왘

Replace key cylinder switch.

Continuity exists

Lock

Key cylinder switch operation

Continuity

Between neutral and lock

Yes

Unlock/neutral

No

NG YEL447B

RH side

왔

CHECK DOOR KEY CYLINDER SWITCH. 1) Disconnect door key cylinder switch connector. 2) Check continuity between door key cylinder switch terminals.

Key cylinder switch Driver side

:

Passenger side:

Terminals

YEL817 1 -쑗 2 쑗

Key position

Continuity

Neutral

No

Between neutral and lock

Yes

Unlock/ neutral

No

Full stroke (Lock)

No

OK 왔

Check the following: ● Harness connectors B3 , M13 ● Harness connectors M7 , D1 ● Harness connectors B5 , D2 ● Harness connectors B56 , D11 ● Door key cylinder switch ground circuit ● Harness for open or short-circuit between super lock control unit and door key cylinder.

EL-338

NG

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 (Smash sensor check) Time control unit connector

YEL457B

1. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Check harness continuity between control unit terminal 쑗 31 and ground. Continuity should exist.

NG

왘

Check the following. ● Smash sensor circuit for open. ● Harness for open between control unit, smash sensors and ground.

OK 왔

1. Disconnect rear window smash sensor connector. 2. Check harness continuity between control unit and ground. Continuity should not exist. NG

Time control unit connector 왔

Check harness for short between control unit and ground.

NEL546

EL-339

OK

왘

Smash sensor is OK.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 (Theft warning horn alarm check) Time control unit connector

YEL465B

Theft warning horn relay connector

CHECK THEFT WARNING HORN ALARM OPERATION. 1. Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Apply ground to control unit connector terminal 쑗 43 . Does horn alarm activate? Refer to wiring diagram EL-319.

Yes

왘

Horn alarm is OK.

No 왔

Check theft warning horn relay.

NG

왘

Replace.

OK YEL466B

왔

CHECK POWER SUPPLY FOR THEFT WARNING HORN RELAY. 1) Disconnect theft warning horn relay connector. 2) Check voltage between terminal 쑗 2 and ground, and 쑗 3 and ground. Battery voltage should exist.

Theft warning horn relay connector

NG

왘

OK 왔 YEL467B

CHECK THEFT WARNING HORN RELAY CIRCUIT. 1. Disconnect theft warning horn relay connector. 2. Check continuity between theft warning horn relay 쑗 1 and control unit terminal 쑗 43 . Continuity should exist. 3. Check continuity between theft warning horn relay 쑗 5 and theft warning horn connector terminal 1 . 쑗 Continuity should exist. OK 왔

Check harness for open or short between theft warning horn relay and control unit.

EL-340

NG

왘

Check the following: ● 10A fuse (No. 16 , located in the fuse and fusible link box) ● Harness for open or short between theft warning horn relay and fuse

Repair harness.

THEFT WARNING SYSTEM Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 (Hazard lamp alarm check) Push hazard switch to ON. Check hazard lamp operation.

Time control unit connector

OK

왘

Replace time control unit.

NG 왔

NEL561

1. Remove time control unit from fuse block (J/B). Remove time control unit from fuse block. Note: Fuse block (J/B) is very fragile. TCU should be removed carefully to avoid breaking the locking bars. 2. Check harness continuity between control unit terminals 쑗 11 and 쑗 15 and ground. Continuity should exist. OK 왔

Replace time control unit.

EL-341

NG

왘

Check the following. ● Harness connectors E104 , B96 ● Fuse block (J/B) ● Turn signal lamps

NATS (Nissan Anti-Theft System) Component Parts Location

YEL039D

EL-342

NATS (Nissan Anti-Theft System) Wiring Diagram — NATS — MODELS BEFORE VIN - P11U0548750 (Type-1) BATTERY

IGNITION SWITCH ON or START

BATTERY

FUSE BLOCK (J/B)

: With gasoline engine : With diesel engine

Refer to EL-POWER.

: With GA engine : With SR engine or QG engine : RHD models AUDIO NATS SECURITY INDICATOR

DONGLE CONTROL UNIT

INJECTION PUMP

: Except

TIME CONTROL UNIT

REFER TO THE FOLLOWING FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B) FUSE BLOCK - Junction Box (J/B)

YEL216C

EL-343

NATS (Nissan Anti-Theft System) Wiring Diagram — NATS — (Cont’d) MODELS AFTER VIN - P11U0548750 (Type-2)

YEL936C

EL-344

NATS (Nissan Anti-Theft System) System Description NATS has the following immobiliser functions: ● This version of NATS has dongle unit to improve its anti-theft performance (RHD models for Europe). Dongle unit has its own ID which is registered into NATS IMMU. So if dongle unit is replaced, initialization must be carried out. ● When malfunction of dongle unit is detected: The security indicator lamp illuminates for about 15 minutes after ignition switch is turned to ON. − When dongle unit has a malfunction, and the indicator lamp is illuminated, engine can not be started. However engine can be started only one time when security indicator lamp turns off in about 15 minutes after ignition switch is turned to ON. ● Since only NATS ignition keys, whose ID nos. have been registered into the ECM and IMMU of NATS, allow the engine to run, operation of a stolen vehicle without a NATS registered key is prevented by NATS. That is to say, NATS will immobilize the engine if someone tries to start it without the registered key of NATS. ● All of the originally supplied ignition key IDs have been NATS registered. If requested by the vehicle owner, a maximum of five key IDs can be registered into the NATS components. ● The NATS security indicator (NATS security ind.) blinks when the ignition switch is in “OFF” or “ACC” position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. ● When NATS detects trouble, the security indicator lamp lights up as follows. Condition IGN ON and

With dongle MIL

Security indicator

—

6 times blinking Staying ON after ignition switch is turned ON

—

Staying ON

—

Staying ON for about 15 minutes after ignition switch is turned ON

—

—

Malfunction of NATS and engine related parts are detected.

Staying ON

6 times blinking Staying ON after ignition switch is turned ON

Staying ON

Staying ON

Only engine related part malfunction is detected.

Staying ON

Staying ON

—

—

—

NATS malfunction (except dongle unit) is detected

Only malfunction of dongle unit is detected.

Just after initialization of NATS ●

●

MIL

Without dongle

—

Security indicator

—

6 times blinking

NATS trouble diagnoses, system initialisation and additional registration of other NATS ignition key IDs must be carried out using CONSULT-II hardware and CONSULT-II NATS software. Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS. When servicing a malfunction of the NATS (indicated by lighting up of security Indicator Lamp) or registering another NATS ignition key ID no., it may be necessary to re-register original key identification. Therefore, be sure to receive all keys and the PIN code from vehicle owner.

EL-345

NATS (Nissan Anti-Theft System) System Composition The immobiliser function of the NATS for Nissan model P11 consists of the following: ● NATS ignition key ● NATS immobiliser control unit (NATS IMMU), located in the ignition key cylinder ● Engine control module (ECM) ● Dongle unit (RHD models for Europe) ● NATS security indicator ● NATS audio link NATS security ind NATS ignition key

NATS IMMU

ECM

DONGLE UNIT (RHD models for Europe)

AUDIO

NEL558

EL-346

NATS (Nissan Anti-Theft System) Data link connector

CONSULT-II CONSULT-II INSPECTION PROCEDURE 1. Turn ignition switch OFF. 2. Connect “CONSULT-II” to Data link connector.

NRS071

3. Insert NATS program card into CONSULT-II. : Program card NATS (AEN00B) 4. Turn ignition switch ON. 5. Touch “START”.

PBR455D

6. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual, NATS.

SEL150X

CONSULT-II DIAGNOSTIC TEST MODE FUNCTION CONSULT-II DIAGNOSTIC TEST MODE

Description

C/U INITIALIZATION

When replacing any of the following components, C/U initialization is necessary. [NATS ignition key/IMMU/ECM/Dongle]

SELF-DIAGNOSTIC RESULTS

Detected items (screen terms) are as shown in the chart below.

NOTE: When any initialisation is performed, all ID previously registered will be erased and all NATS ignition keys must be registered again. The engine cannot be started with an unregistered key. In this case, the system may show “DIFFERENCE OF KEY” or “LOCK MODE” as a self-diagnostic result on the CONSULT-II screen. When initialisation is performed for RHD models for Europe, security indicator will flash six times to demonstrate recognition of dongle ID.

EL-347

NATS (Nissan Anti-Theft System) CONSULT-II (Cont’d) HOW TO READ SELF-DIAGNOSTIC RESULTS

SEL308W

NATS SELF-DIAGNOSTIC RESULTS ITEM CHART Detected items (NATS program card screen terms)

P No. Code (Self-diagnostic result of “ENGINE”)

Malfunction is detected when ...

Reference page

ECM INT CIRC-IMMU

NATS MALFUNCTION P1613

The malfunction of ECM internal circuit of IMMU communication line is detected.

EL-352

CHAIN OF ECM-IMMU

NATS MALFUNCTION P1612

Communication impossible between ECM and IMMU

EL-353

DIFFERENCE OF KEY

NATS MALFUNCTION P1615

IMMU can receive the key ID signal but the result of ID verification between key ID and IMMU is NG.

EL-355

CHAIN OF IMMU-KEY

NATS MALFUNCTION P1614

IMMU cannot receive the key ID signal. Or the registered ID signal from dongle unit can not be received when the IMMU request the ID.

EL-356

ID DISCORD, IMM-ECM

NATS MALFUNCTION P1611

The result of ID verification between IMMU and ECM is NG. System initialization is required.

EL-358

All engine trouble codes except NATS trouble code have been detected in ECM.

EL-349

When the starting operation is carried out five or more times consecutively under the following conditions, NATS will shift the mode to one which prevents the engine from being started. ● Unregistered ignition key is used. ● IMMU or ECM is malfunctioning.

EL-361

DON’T ERASE BEFORE CHECKING ENG DIAG

LOCK MODE

—

NATS MALFUNCTION P1610

EL-348

NATS (Nissan Anti-Theft System) Trouble Diagnoses WORK FLOW CHECK IN 왔

Listen to customer complaints or request. (Get symptoms) TROUBLE

KEY SERVICE REQUEST (Additional key ID registration) 왔

왔

Verify the security indicator and MI*.

INITIALISATION (Refer to CONSULT-II operation manual NATS.)

왔 왘

Using the CONSULT-II program card for NATS check the “SELF-DIAG RESULTS” with CONSULT-II.

왗

왔

왔

왔

Self-diagnostic results referring to NATS and “DON’T ERASE BEFORE CHECKING ENG DIAG” are displayed on CONSULT-II. (This means that engine trouble data has been detected in ECM.)

왔

Turn ignition switch “OFF”.

Self-diagnostic results referring to NATS, but no information about engine self-diagnostic results is displayed on CONSULT-II.

Turn ignition switch “OFF”.

왔

Repair NATS. (If necessary, carry out “C/U INITIALIZATION” with CONSULT-II.) 왔

Turn ignition switch “ON”.

왔

왔

Erase the NATS “SELF-DIAG RESULTS” by using CONSULT-II. (Touch “ERASE”.)

Do not erase the NATS “SELF-DIAG RESULTS” by using CONSULT-II. 왔

왔

Check the engine “SELF-DIAG RESULTS” with CON왗 SULT-II by using the CONSULT-II generic program card. (Engine diagnostic software included)

Start the engine.

NG

왔

Repair NATS according to self-diagnostic results referring to NATS. (If necessary, carry out “C/U INITIALIZATION” with CONSULT-II.)

왔

Verify no lighting up of the security indicator. 왔

OK

CHECK OUT

왔

Repair engine control system (Refer to EC section.) when self-diagnostic results except “NATS MALFUNCTION” are detected. When only “NATS MALFUNCTION” is detected, erase the self-diagnostic results and go to the next step.

왔

Perform running test with CONSULT-II in engine “SELFDIAG RESULTS” mode.

왔

Start the engine. Does the engine start properly? 왔

왔

NG Verify “NO DTC IS DETECTED” displayed on the CONSULT-II screen. 왔

OK

Erase the NATS and engine “SELF-DIAG RESULTS” by using the CONSULT-II program card for NATS and generic program card.

OK 왔

CHECK OUT Start the engine.

EL-349

NG

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 1 (Self-diagnosis related item) SYMPTOM ● ●

Security indicator lighting up* Engine does not start

Displayed “SELF-DIAG RESULTS” on CONSULT-II screen ECM INT CIRC-IMMU

CHAIN OF ECM-IMMU

● ●

Security indicator lighting up* Engine does not start

DIFFERENCE OF KEY

CHAIN OF IMMU-KEY

ID DISCORD, IMM-ECM

LOCK MODE ● ●

MI staying ON Security indicator lighting up*

DON’T ERASE BEFORE CHECKING ENG DIAG

DIAGNOSTIC PROCEDURE (Reference page) PROCEDURE 1 (EL-352)

PROCEDURE 2 (EL-353)

PROCEDURE 3 (EL-355)

PROCEDURE 4 (EL-356)

PROCEDURE 5 (EL-358) PROCEDURE 7 (EL-361) WORK FLOW (EL-349)

SYSTEM (Malfunctioning part or mode)

ECM

REFERENCE PART NO. OF ILLUSTRATION ON NEXT PAGE B

Open circuit in battery voltage line of IMMU circuit

C1

Open circuit in ignition line of IMMU circuit

C2

Open circuit in ground line of IMMU circuit

C3

Open circuit in communication line between IMMU and ECM

C4

Short circuit between IMMU and ECM communication line and battery voltage line

C4

Short circuit between IMMU and ECM communication line and ground line

C4

ECM

B

IMMU

A

Unregistered key

D

IMMU

A

Malfunction of key ID chip

E

IMMU

A

Open circuit in ground line of dongle circuit

C6

Open or short circuit in communication line between IMMU and dongle unit

C5

Dongle control unit

G

System initialisation has not yet been completed.

F

ECM

B

LOCK MODE

D

Engine trouble data and NATS trouble data have been detected in ECM.

—

*: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position. *: When the vehicle is equipped with dongle unit (RHD models for Europe), the security indicator blinks 6 times just after ignition switch is turned to ON. Then the security indicator lights up while ignition key is in the “ON” position.

EL-350

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 2 (Non self-diagnosis related item) DIAGNOSTIC PROCEDURE (Reference page)

SYMPTOM

REFERENCE PART NO. OF ILLUSTRATION ON NEXT PAGE

SYSTEM (Malfunctioning part or mode) Security ind.

●

Open circuit between Fuse and NATS IMMU

PROCEDURE 6 (EL-360)

Security ind. does not light up.

Continuation of initialization mode NATS IMMU Security ind. does not blink just after initialization even if the vehicle is equipped with dongle unit.

NATS might be initialized without connecting dongle unit properly.

PROCEDURE 8 (EL-362)

Security ind. does not blink just after ignition switch is turned to ON when some malfunction related to NATS is detected even if the vehicle is equipped with dongle unit.

Open circuit in ground line of dongle circuit

C6

Open or short circuit in communication line between IMMU and dongle unit

C5

Dongle control unit

G

DIAGNOSTIC SYSTEM DIAGRAM PART D

Key ID chip (PART E)

Security indicator

PART C2 PART C1

PART C5 PART C4

NATS ignition key

PART G

PART A

PART B

PART F PART C6

PART C3

NEL559

EL-351

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 Self-diagnostic results: “ECM INT CIRC-IMMU” displayed on CONSULT-II screen Confirm SELF-DIAGNOSTIC RESULTS “ECM INT CIRC-IMMU” displayed on CONSULT-II screen. Ref. part No. B. 왔

Replace ECM.

SEL314W

왔

Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.

EL-352

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 SELF DIAGNOSIS DTC RESULTS

Self-diagnostic results: “CHAIN OF ECM-IMMU” displayed on CONSULT-II screen

TIME

CHAIN OF ECM-IMMU

0

Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF ECMIMMU” displayed on CONSULT-II screen. OK YEL471B 왔

CHECK POWER SUPPLY CIRCUIT FOR IMMU. Check voltage between IMMU terminal 8 and ground. 쑗 Battery voltage should exist.

IMMU connector

NG

왘

OK

YEL472B

왔

CHECK IGN SW. ON SIGNAL. Check voltage between IMMU terminal 7 and ground while ignition switch is 쑗 “ON” position. Battery voltage should exist.

IMMU connector

NG

왘

OK

왔 YEL473B

CHECK GROUND CIRCUIT FOR IMMU. Check continuity between IMMU terminal 쑗 4 and ground. Continuity should exist.

Check the following. 10A fuse [No. 12 , located in the fuse block (J/B)] ● Harness for open or short between fuse and IMMU connector Ref. part No. C2 ●

왘

Repair harness. Ref. part No. C3

왘

Repair harness. Ref. part No. C4

OK

IMMU connector 왔

YEL474B

CHECK COMMUNICATION OPEN CIRCUIT. Check continuity between IMMU termi116 (Gasonal 쑗 1 and ECM terminal line engine) or 410 (Diesel engine). Continuity should exist. OK 왔

ECM connector

NG

Check the following. 10A fuse (No. 39 : gasoline engine, located in the fuse and fusible link box) ● Harness for open or short between fuse and IMMU connector Ref. part No, C1 ●

IMMU connector

A 쑗

NEL762

EL-353

NG

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) A 쑗

IMMU connector

왔

CHECK COMMUNICATION LINE SHORT CIRCUIT. 1. Disconnect ECM connector and IMMU connector. 2. Check continuity between IMMU terminal 쑗 1 and ground. Continuity should not exist. 3. Turn ignition switch to ON. 4. Check voltage between IMMU terminal 쑗 1 and ground. No voltage should exist.

Short to ground check

IMMU connector

NG

왘

Repair harness. Ref. part No. C4

OK 왔

Short to power circuit check YEL476B

Check the signal from ECM to IMMU. 1. Check the signal between ECM terminal 쑗 116 and ground with CONSULT-II or oscilloscope when ignition switch is turned ON. 2. Some signals can be detected during 750 msec. just after ignition switch is turned “ON”. OK 왔

IMMU is malfunctioning. 1. Replace IMMU. Ref. part No. A 2. Perform initialization with CONSULTII. For the initialization procedure, refer to “CONSULT-II operation manual NATS”.

NEL543

EL-354

NG

왘

ECM is malfunctioning. 1. Replace ECM. Ref part No. B 2. Perform initialization procedure, refer to “CONSULT-II operation manual NATS”.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 SELF DIAGNOSIS DTC RESULTS

Self-diagnostic results: “DIFFERENCE OF KEY” displayed on CONSULT-II screen

TIME

DIFFERENCE OF KEY

0

Confirm SELF-DIAGNOSTIC RESULTS “DIFFERENCE OF KEY” displayed on CONSULT-II screen. OK 왔

YEL478B

PERFORM INITIALISATION. Perform initialisation with CONSULT-II. Re-register all NATS ignition key IDs. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is not completed or fails, CONSULT-II shows message on the screen.

IMMU INITIALIZATION

INITIALIZATION FAIL

THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.

Yes YEL479B

왔

Start engine. 왔

END (Ignition key ID had been unregistered.)

EL-355

No

왘

IMMU is malfunctioning. 1. Replace IMMU. Ref. part No. A 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. ●

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 SELF DIAGNOSIS DTC RESULTS

CHAIN OF IMMU-KEY

Self-diagnostic results: “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen

TIME

0

Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF IMMUKEY” displayed on CONSULT-II screen. OK YEL480B

왔

CHECK NATS IGNITION KEY ID CHIP. Can the engine start with another registered NATS ignition key?

Yes

왘

No

왔

CHECK NATS IMMU INSTALLATION. Refer to “How to Replace NATS IMMU” in EL-363.

NG

왘

Ignition key ID chip is malfunctioning. 1. Replace the ignition key. Ref. part No. E 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. ●

Reinstall NATS IMMU correctly.

OK 왔

Is this vehicle equipped with dongle unit (RHD models for Europe)? Yes

왔

A 쑗

EL-356

No

왘

IMMU is malfunctioning. 1. Replace IMMU. Ref part No. A 2. Perform initialisation with CONSULT-II For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) A 쑗

Dongle unit connector

왔

CHECK HARNESS CONNECTOR CONNECTION. Check the following harness connector connection. E125 / M70

Yes

왘

System is OK. (The malfunction is caused by improper connector connection.)

M85 SEL417W

Does the engine start? No 왔

IMMU connector

Dongle unit connector

CHECK GROUND CIRCUIT FOR DONGLE UNIT. Check continuity between dongle unit terminal 쑗 3 and ground. Continuity should exist.

No

왘

Repair harness.

Yes 왔 Short circuit check

SEL418W

IMMU connector

CHECK INTERFACE CIRCUIT. 1. Check continuity between IMMU terminal 쑗 2 and dongle unit terminal 5 (Open circuit check) 쑗 Continuity should exist. 2. Check continuity between IMMU terminal 쑗 2 and ground. (Short circuit check) Continuity should not exist. Yes 왔

Short circuit check SEL419W

Dongle unit is malfunctioning. 1. Replace dongle unit. 2. Perform initialisation with CONSULTII. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.

EL-357

No

왘

Repair harness.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 Self-diagnostic results: “ID DISCORD, IMM-ECM” displayed on CONSULT-II screen Confirm SELF-DIAGNOSTIC RESULTS “ID DISCORD, IMMECM*” displayed on CONSULT-II screen.

C2SDD01

왔

PERFORM INITIALISATION. Perform initialisation with CONSULT-II. Re-register all NATS ignition key IDs. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is not completed or fails, CONSULT-II message on the shows screen.

IMMU INITIALIZATION

INITIALIZATION FAIL

THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.

Yes YEL479B

왔

Start engine. (END) (System initialisation was not completed. Ref. part No. F)

EL-358

* “ID DISCORD, IMM-ECM”: Registered ID of IMMU is in discord with that of ECM.

No

왘

● ECM is malfunctioning. 1. Replace ECM. Ref. part No. B 2. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 — With security indicator on dashboard — “SECURITY INDICATOR LAMP DOES NOT LIGHT UP”

Security indicator lamp connector

Check 10A fuse [No. 16 , located in the fuse block (J/B)].

NG

왘

Replace fuse.

OK 왔

YEL482B

IMMU connector

NATS INITIALISATION 1) Install the 10A fuse. 2) Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”. 왔

Turn ignition switch “OFF”. 왔 YEL483B

Start engine and turn ignition switch “OFF”. 왔

Check the security ind. lighting.

OK

왘

INSPECTION END

NG 왔

Check voltage between security indicator lamp connector terminal 쑗 2 and ground. Voltage: Battery voltage

NG

왘

Check harness for open or short between fuse and security indicator lamp.

OK 왔

CHECK INDICATOR LAMP.

NG

왘

Replace indicator lamp.

OK 왔

CHECK NATS IMMU FUNCTION. 1. Connect NATS IMMU connector. 2. Disconnect security indicator lamp connector. 3. Check continuity between NATS IMMU terminal 쑗 6 and ground. Continuity should exist intermittently. OK

왔

Check harness for open or short between security indicator and NATS IMMU.

EL-359

NG

왘

NATS IMMU is malfunctioning. Replace IMMU. 왔

Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 — With security indicator built-in combination meter — “SECURITY INDICATOR LAMP DOES NOT LIGHT UP” Check 10A fuse [No. 16 , located in the fuse block (J/B)].

NG

왘

Replace fuse.

OK 왔 YEL037D

IMMU connector

NATS INITIALISATION 1) Install the 10A fuse. 2) Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”. 왔

Turn ignition switch “OFF”.

YEL483B

왔

Start engine and turn ignition switch “OFF”. 왔

Check the security ind. lighting.

OK

왘

INSPECTION END

NG 왔

Check voltage between combination meter connector terminal 쑗 2 and ground. Voltage: Battery voltage

NG

왘

Check harness for open or short between fuse and combination meter.

OK 왔

CHECK INDICATOR LAMP.

NG

왘

Replace combination meter.

왘

NATS IMMU is malfunctioning. Replace IMMU.

OK 왔

CHECK NATS IMMU FUNCTION. 1. Connect NATS IMMU connector. 2. Disconnect combination meter connector. 3. Check continuity between NATS IMMU terminal 쑗 6 and ground. Continuity should exist intermittently. OK

왔

Check harness for open or short between combination meter and NATS IMMU.

EL-360

NG

왔

Perform initialisation with CONSULT-II. For the operation of initialisation, refer to “CONSULT-II operation manual NATS”.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 SELF DIAGNOSIS DTC RESULTS

Self-diagnostic results: “LOCK MODE” displayed on CONSULT-II screen

TIME

LOCK MODE

0

Confirm SELF-DIAGNOSTIC RESULTS “LOCK MODE” is displayed on CONSULT-II screen. 왔 YEL484B

IMMU INITIALIZATION

INITIALIZATION FAIL

THEN IGN KEY SW ‘OFF’ AND ‘ON’, AFTER CONFIRMING SELF-DIAG AND PASSWORD, PERFORM C/U INITIALIZATION AGAIN.

1. Turn the ignition switch to OFF position. 2. Turn the ignition key switch to ON position with a registered key. (Do not start engine.) Wait for 5 seconds. 3. Return the key to the OFF position. 4. Repeat steps 2 and 3 twice (total of three cycles). 5. Start the engine. Can the engine start?

Yes

왘

System is OK. (Now the system is escaped from “LOCK MODE”.)

No YEL479B

왔

CHECK NATS IMMU INSTALLATION. Refer to “How to Replace NATS IMMU” in EL-363.

NG

왘

Reinstall NATS IMMU correctly.

OK 왔

PERFORM INITIALISATION. Perform initialisation with CONSULT-II. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”. Can the system be initialized? Note: If the initialisation is incompleted or failed, CONSULT-II shows message on the screen. No 왔

Go to DIAGNOSTIC PROCEDURE 4, EL-356 to check “CHAIN OF IMMUKEY”.

EL-361

Yes

왘

System is OK.

NATS (Nissan Anti-Theft System) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 8 Perform initialization with CONSULT-II Check the following harness connector connection. E125 / M70

Dongle unit connector

Yes

왘

System is OK. (The malfunction is caused by improper connector connection.)

M85

SEL417W

Then initialize NATS. For the operation of initialization, refer to “CONSULT-II operation manual NATS”. Does the security indicator blink just after the initialization? No 왔

IMMU connector

Dongle unit connector

CHECK GROUND CIRCUIT FOR DONGLE UNIT. Check continuity between dongle unit terminal 쑗 3 and ground. Continuity should exist.

No

왘

Repair harness.

Yes 왔 Short circuit check

SEL418W

IMMU connector

CHECK INTERFACE CIRCUIT. 1. Check continuity between IMMU terminal 쑗 2 and dongle unit terminal 5 (Open circuit check) 쑗 Continuity should exist. 2. Check continuity between IMMU terminal 쑗 2 and ground. (Short circuit check) Continuity should not exist. Yes 왔

Short circuit check SEL419W

Dongle unit is malfunctioning. 1. Replace dongle unit. 2. Perform initialisation with CONSULTII. For the initialisation procedure, refer to “CONSULT-II operation manual NATS”.

EL-362

No

왘

Repair harness.

NATS (Nissan Anti-Theft System) NVIS (NATS) IMMU

How to Replace NATS IMMU NOTE: ● If NATS IMMU is not installed correctly, NATS system will not operate properly and SELF-DIAG RESULTS on CONSULT-II screen will show “LOCK MODE” or “CHAIN OF IMMU-KEY”.

SEL096WA

EL-363

NATS (Nissan Anti-Theft System) NOTE

EL-364

LOCATION OF ELECTRICAL UNITS Engine Compartment Front wiper motor (LHD models)

Front wiper motor (RHD models)

Relay box ABS actuator and electric unit (Control unit)

Fusible link and fuse box

Glow relay (CD engine models)

Headlamp relay LH Horn relay Cooling fan relay-3 ECM relay

Cooling fan relay-1 Cooling fan relay-2 or power fuse

Accessory relay Glow relay (CD engine models)

Park/Neutral position relay Air conditioner relay Rear wiper relay Headlamp relay RH Front wiper relay YEL234C

EL-365

LOCATION OF ELECTRICAL UNITS Passenger Compartment LHD MODELS

NATS IMMU Auto level control unit Headlamp washer timer

Daytime light control unit

Indicator control unit

Stop lamp switch

Time control unit

Fuse block (J/B) Time control unt

Blower relay Circuit breaker-1

Ignition relay

Circuit breaker-2

Theft warning horn relay

Air bag diagnosis sensor unit TCM (Transmission control module)

Fuse block (J/B) Rear window defogger relay Power window relay

ECM A/C LOW relay, A/C MED-LOW relay, A/C MED-HIGH relay, A/C HIGH relay

Front fog lamp relay Fuel pump relay YEL235C

EL-366

LOCATION OF ELECTRICAL UNITS Passenger Compartment (Cont’d) RHD MODELS

Headlamp washer timer

NATS IMMU Indicator control unit

Stop lamp switch

Auto level control unit

Time control unit

Fuse block (J/B) Time control unit

Ignition relay Circuit breaker-1 Blower relay

Circuit breaker-2 Theft warning horn relay Air bag diagnosis sensor unit

Fuse block (J/B)

TCM (Transmission control module) ECM A/C LOW relay. A/C MED-LOW relay. A/C MED-HIGH relay. A/C HIGH relay

Fuel pump relay Front fog lamp relay Power window relay Rear window defogger relay

YEL236C

EL-367

HARNESS LAYOUT Outline

LHD MODELS

Room lamp harness

Rear door harness RH (5-door Hatchback and Wagon)

Back door harness

Front door harness RH Main harness

Hatchback and Wagon

Rear door harness LH (5-door Hatchback and Wagon) Tail harness Tail sub harness Tail harness No. 2 Rear door harness RH Body harness Front door harness LH Console harness Engine room harness Air conditioner harness Engine control harness

Sedan Rear door harness LH Body harness Console harness YEL367B

RHD MODELS Rear door harness RH (5-door Hatchback and Wagon)

Room lamp harness Back door harness

Front door harness RH Main harness

Hatchback and Wagon Rear door harness LH (5-door Hatchback and Wagon) Tail harness Tail sub harness Tail harness No. 2 Rear door harness RH Body harness Front door harness LH Console harness Engine room harness Air conditioner harness Engine control harness

Sedan Rear door harness LH Body harness Console harness

EL-368

YEL237C

HARNESS LAYOUT How to Read Harness Layout Example: G2

E1

B/6

: ASCD ACTUATOR

Connector color / Cavity Connector number Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings: ● Engine Room Harness (Engine Compartment) ● Main Harness ● Body Harness To 1) 2) 3) 4) 5)

use the grid reference Find the desired connector number on the connector list. Find the grid reference. On the drawing, find the crossing of the grid reference letter column and number row. Find the connector number in the crossing zone. Follow the line (if used) to the connector.

CONNECTOR SYMBOL Main symbols of connector (in Harness Layout) are indicated in the below. Connector type

●

Cavity: Less than 4 Relay connector

●

Cavity: From 5 to 8

●

Cavity: More than 9

●

Ground terminal etc.

●

Water proof type Male

Female

—

—

Standard type Male

—

EL-369

Female

HARNESS LAYOUT Engine Control Harness QG ENGINE

YEL957C

EL-370

HARNESS LAYOUT Engine Control Harness (Cont’d)

YEL958C

EL-371

HARNESS LAYOUT Engine Control Harness (Cont’d) SR20DE ENGINE

YEL959C

EL-372

HARNESS LAYOUT Engine Control Harness (Cont’d)

YEL960C

EL-373

CD20T ENGINE

Body ground

Engine ground

LHD models

Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

HARNESS LAYOUT Engine Control Harness (Cont’d)

EL-374

RHD models

YEL243C

HARNESS LAYOUT Engine Control Harness (Cont’d)

YEL962C

EL-375

HARNESS LAYOUT Engine Room Harness ENGINE COMPARTMENT — LHD models

YEL963C

EL-376

HARNESS LAYOUT Engine Room Harness (Cont’d)

YEL964C

EL-377

HARNESS LAYOUT Engine Room Harness (Cont’d) ENGINE COMPARTMENT — RHD models

YEL965C

EL-378

HARNESS LAYOUT Engine Room Harness (Cont’d)

YEL966C

EL-379

HARNESS LAYOUT Engine Room Harness (Cont’d) PASSENGER COMPARTMENT — LHD models

YEL967C

EL-380

HARNESS LAYOUT Engine Room Harness (Cont’d) PASSENGER COMPARTMENT — RHD models

YEL968C

EL-381

HARNESS LAYOUT Main Harness LHD MODELS

YEL969C

EL-382

HARNESS LAYOUT Main Harness (Cont’d)

YEL970C

EL-383

HARNESS LAYOUT Main Harness (Cont’d) RHD MODELS

YEL971C

EL-384

HARNESS LAYOUT Main Harness (Cont’d)

YEL972C

EL-385

★

Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

Body ground

HARNESS LAYOUT

Body ground

Body Harness

EL-386 Body ground

SEDAN — LHD models before VIN - P11U0548750

.

YEL253C

Body harness B3 B4 B5 B8 B11 B12 B15 B16 B17 B18 B19 B20 B21 B22 B24 B26 B27 B28 B29 B30 B31 B32 B33 B34 B37 B38 B40 B47 B50 B51 B52 B53 B54 B56 B57 B58 B59 B61 B65 B66 B67 B68

YEL254C

B69 B70

W/24 W/6 W/12 BR/16 W/8 W/20 W/6 W/8 W/4 — BR/1 B/3 W/3 W/2 B/1 W/4 — W/8 W/8 GY/2 GY/3 GY/2 BR/2 BR/1 B/2 BR/1 B/2 W/16 B/1 W/2 W/4 W/8 W/8 W/10 W/16 W/12 B/1 W/3 — Y/12 Y/12 Y/2 Y/2 OR/2

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

To M13 To M14 To D2 Fuse block (J/B) Time control unit Time control unit Ultra sonic sub-sensor To D22 Seat belt pre-tensioner (Passenger side) Body ground Front door switch (Passenger side) Front door switch (Driver’s side) Heated seat LH Power seat Parking brake switch Seat belt pre-tensioner (Driver’s side) Body ground To D18 Ultra sonic sensor Fuel pump Fuel level sensor unit Rear wheel sensor RH Rear wheel sensor LH Rear door switch RH Rear speaker RH Rear door switch LH Rear speaker LH CD auto changer High mounted stop lamp Trunk room lamp Rear wiper motor To T1 To T14 To D11 To E115 To B101 Rear window defogger Heated seat RH Body ground Diagnosis sensor unit Diagnosis sensor unit Side air bag module LH Side air bag module RH Satellite sensor LH

D2 D2 B1 A3 A3 A1 C3 C2 C4 C4 B2 D4 F3

B71 B72 B97 B98 B99 B121 B122 B123 B124 B130 B131 B132 B133

Y/2 — B/2 L/4 GY/2 W/6 W/3 W/12 W/3 W/3 −/3 W/3 −/3

: : : : : : : : : : : : :

Satellite sensor RH Body ground Fuse block (J/B) Theft warning horn relay Circuit breaker-2 Central unlock/trunk release switch To B130 Auto level control unit To B132 To B122 Front sensor To B124 Rear sensor

Console harness C2 C2 B3 C2 C2

B101 B102 B104 B105 B106

W/12 W/6 L/4 W/4 W/4

: : : : :

To B58 Ultrasonic cancel switch Heated seat switch LH Heated seat switch RH Headlamp aiming switch

: : : : : : : : : :

To B53 Rear combination lamp LH Body ground Body ground Rear combination lamp RH Theft warning horn License plate lamp LH Not used (To trailer tow connection) Link License plate lamp RH

Tail harness E3 F4 F3 G3 G3 G2 F4 D4 E4 F3

T1 T2 T3 T4 T5 T6 T9 T17 T18 T19

W/8 W/4 — — W/4 B/1 BR/2 BR/4 BR/4 BR/2

Tail harness No. 2 F3 F4 G3 G2 G2 G3

T7 T8 T10 T12 T13 T20

W/8 W/2 B/2 W/4 W/2 W/3

: : : : : :

To T16 Rear fog lamp Trunk room lamp switch Door unlock actuator assembly (Trunk) Back-up lamp External trunk release switch

Tail sub-harness E4 E4

T14 T16

W/8 W/8

: :

To B54 To T7

HARNESS LAYOUT Body Harness (Cont’d)

EL-387

A3 A2★ A1 B2 A1 A1 D1 E1 E2 E1 D2 B3 B4 C4 C2 B4 B2 B2 B3 D4 D4★ E3 D4 E1 F2 D3 E2 D2 F2 F3 F3 E3 E3 C1 C1 C2 D1 D3 B3 C3 C3 B4 D3 B4

HARNESS LAYOUT Body Harness (Cont’d) SEDAN — LHD models after VIN - P11U0548750

YEL973C

EL-388

HARNESS LAYOUT Body Harness (Cont’d)

YEL974C

EL-389

Body ground

Body ground

.

★

Be sure to connect and lock the connectors securely after repair work. Failure to do so may cause the ECM to have diagnostic trouble codes. Do not disconnect these connectors except in the case of working according to WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

HARNESS LAYOUT Body Harness (Cont’d)

SEDAN — RHD models before VIN - P11U0548750

EL-390 Body ground

YEL255C

Body harness B3 B4 B5 B8 B11 B12 B15 B16 B17 B18 B19 B20 B21 B22 B24 B26 B27 B28 B29 B30 B31 B32 B33 B34 B37 B38 B40 B47 B50 B51 B52 B53 B54 B56 B57 B58 B59 B61 B65 B66 B67 B68

YEL256C

B69 B70

W/24 W/6 W/12 BR/16 W/8 W/20 W/6 W/8 W/4 — BR/1 B/3 W/3 W/2 B/1 W/4 — W/8 W/8 GY/2 GY/3 GY/2 BR/2 BR/1 B/2 BR/1 B/2 W/16 B/1 W/2 W/4 W/8 W/8 W/10 W/16 W/12 B/1 W/3 — Y/12 Y/12 Y/2 Y/2 OR/2

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

To M13 To M14 To D2 Fuse block (J/B) Time control unit Time control unit Ultra sonic sub-sensor To D22 Seat belt pre-tensioner (Driver’s side) Body ground Front door switch (Passenger side) Front door switch (Driver’s side) Heated seat LH Power seat Parking brake switch Seat belt pre-tensioner (Passenger side) Body ground To D18 Ultra sonic sensor Fuel pump Fuel level sensor unit Rear wheel sensor RH Rear wheel sensor LH Rear door switch RH Rear speaker RH Rear door switch LH Rear speaker LH CD auto changer High mounted stop lamp Trunk room lamp Rear wiper motor To T1 To T14 To D11 To E115 To B101 Rear window defogger Heated seat RH Body ground Diagnosis sensor unit Diagnosis sensor unit Side air bag module LH Side air bag module RH Satellite sensor LH

F4 F3 F1 G3 G3 G1 D3 E1 B2 D3 F2 B2 B3

B71 B72 B97 B98 B99 B121 B122 B123 B124 B130 B131 B132 B133

Y/2 — B/2 L/4 GY/2 W/6 W/3 W/12 W/3 W/3 —/3 W/3 —/3

: : : : : : : : : : : : :

Satellite sensor RH Body ground Fuse block (J/B) Theft warning horn relay Circuit breaker-2 Central unlock/trunk release switch To B130 Auto level control unit To B132 To B122 Front sensor To B124 Rear sensor

Console harness E2 D2 D2 E2 E2

B101 B102 B104 B105 B106

W/12 W/6 L/4 W/4 W/4

: : : : :

To B58 Ultrasonic cancel switch Heated seat switch LH Heated seat switch RH Headlamp aiming switch

: : : : : : : : : :

To B53 Rear combination lamp LH Body ground Body ground Rear combination lamp RH Theft warning horn License plate lamp LH Not used (To trailer tow connection) Link License plate lamp RH

Tail harness A2 A3 B4 B4 B4 C4 A3 A3 A3 A3

T1 T2 T3 T4 T5 T6 T9 T17 T18 T19

W/8 W/4 — — W/4 B/1 BR/2 BR/4 BR/4 BR/2

Tail harness No. 2 A3 A3 B3 C3 B3 B3

T7 T8 T10 T12 T13 T20

W/8 W/2 B/2 W/4 W/2 W/3

: : : : : :

To T16 Back-up lamp Trunk room lamp switch Door unlock actuator assembly (Trunk) Rear fog lamp External trunk release switch

Tail sub-harness A2 A2

T14 T16

W/8 W/8

: :

To B54 To T7

HARNESS LAYOUT Body Harness (Cont’d)

EL-391

G3 G3★ G2 F1 F1 G1 F3 F2 E4 F2 D1 F3 C3 E3 E3 C1 C2 D1 C1 D4 D3★ E4 C2 D1 C1 C1 B1 A1 B1 B2 C1 A2 A2 E1 E1 E2 B1 E3 C2 D3 E3 C3 E3 C2

HARNESS LAYOUT Body Harness (Cont’d) SEDAN — RHD models after VIN - P11U0548750

YEL975C

EL-392

HARNESS LAYOUT Body Harness (Cont’d)

YEL976C

EL-393

HARNESS LAYOUT Body Harness (Cont’d) 5-DOOR HATCHBACK — LHD models

YEL977C

EL-394

HARNESS LAYOUT Body Harness (Cont’d)

YEL978C

EL-395

HARNESS LAYOUT Body Harness (Cont’d) 5-DOOR HATCHBACK — RHD models

YEL979C

EL-396

HARNESS LAYOUT Body Harness (Cont’d)

YEL980C

EL-397

HARNESS LAYOUT Body Harness (Cont’d) WAGON — LHD MODELS

YEL981C

EL-398

HARNESS LAYOUT Body Harness (Cont’d)

YEL982C

EL-399

HARNESS LAYOUT Body Harness (Cont’d) WAGON — RHD models

YEL983C

EL-400

HARNESS LAYOUT Body Harness (Cont’d)

YEL984C

EL-401

HARNESS LAYOUT LHD MODELS

Air Conditioner Harness

YEL985C

RHD MODELS

YEL986C

EL-402

R1 R2 R3 R4 R5 R6 R8 R9 R10

W/6 B/2 W/2 W/8 W/2 W/2 W/2 B/2 W/6

: : : : : : : : :

To M15 (RHD models) Vanity mirror lamp (RHD models) Sunroof motor Sunroof switch Spot lamp Interior lamp (Without sunroof) Interior lamp (With sunroof) Vanity mirror lamp (LHD models) Fuse block (J/B) (LHD models)

HARNESS LAYOUT

Room Lamp Harness

EL-403 .

YEL267C

HARNESS LAYOUT Back Door Harness 5-DOOR HATCHBACK

YEL988C

EL-404

HARNESS LAYOUT Back Door Harness (Cont’d) WAGON

D108

D109

D110 D116

D107

D105 D102

D106 D104

D113

D101

.

D101 D101 D102 D102 D104 D104 D105 D105 D106 D106 D107

D107

D108

D108

D109

D109

D110

D110

D113

D113

D116

D116

W/4 W/4 W/6 W/6 W/4 W/4 W/2 W/2 W/2 W/2 W/4 W/4 W/4 W/4 W/4 W/4 — – B/1 B/1 W/2 W/2

: : : : : : : : : : :

B42 : To B42 B43 : To B43 : Rear combination lamp LH : Luggage room lamp switch : Licence plate lamp LH : Rear wiper motor Rear combination lamp RH : Door lock actuator assembly : Body ground : Rear window defogger : Licence plate lamp RH :

Body ground

D110

YEL405B

EL-405

HARNESS LAYOUT LHD MODELS

Front Door Harness (LH side)

YEL989C

RHD MODELS

YEL990C

EL-406

HARNESS LAYOUT LHD MODELS

Front Door Harness (RH side)

YEL991C

RHD MODELS

YEL992C

EL-407

HARNESS LAYOUT LH SIDE

Rear Door Harness

YEL993C

RH SIDE

YEL994C

EL-408

ALPHABETICAL INDEX SECTION

IDX

IDX

ALPHABETICAL INDEX A

B

AAC/V - Wiring diagram....EC-QG-276, EC-SR-265 ABS (anti-lock brake system).........................BR-50 A/C control linkage adjustment (manual A/C).............................................................HA-82 A/C control operation (auto A/C) ....................HA-19 A/C diagnostic work flow (auto A/C) ..............HA-26 A/C performance chart ...................................HA-35 A/C performance test diagnoses....................HA-33 A/C relay.........................................................HA-78 A/C service data specification ......................HA-118 A/C switch ......................................................HA-78 A/C symptom chart (auto A/C) .......................HA-28 A/C trouble diagnoses (auto A/C) ..................HA-26 Accelerator control system ...............................FE-3 Accelerator position sensor ...................EC-CD-108 Accelerator position switch ....................EC-CD-108 Accelerator wire adjustment .............................FE-4 A/CCUT - Wiring diagram ......................EC-CD-127 Air bag disposal..............................................RS-27 Air bag precautions ...........................................GI-3 Air bleeding for brake system ..........................BR-8 Air cleaner filter replacement ............MA-23, 34, 44 Air conditioner cut control.....EC-QG-24, EC-SR-26, EC-CD-20, 126 Air flow meter - See Mass air flow sensor ............................EC-QG-110, EC-SR-120 Air mix. door motor.........................................HA-92 Alternator ..................................................EL-53, 56 Ambient sensor ..............................................HA-86 Antenna.........................................................EL-229 Anti-lock brake system - See ABS .................BR-50 APS - Wiring diagram ............................EC-CD-109 A/T - Wiring diagram - AT - FTS .....................AT-56 A/T - Wiring diagram - AT - MAIN...................AT-45 A/T - Wiring diagram - AT - PNP/SW..............AT-50 A/T - Wiring diagram - AT - VSS A/T ..............AT-64 A/T diagnosis communication line .........EC-SR-295 A/T fluid temperature sensor...........................AT-54 A/T trouble diagnoses ...............................AT-29, 30 A/T Wiring diagram - AT - ENG SS ................AT-67 A/T Wiring diagram AT - LPSV .......................AT-76 A/T Wiring diagram AT - TCV .........................AT-71 A/T Wiring diagram AT - TPS..........................AT-81 ATDIAG - Wiring diagram ......................EC-SR-296 Audio .............................................................EL-216 AUDIO - Wiring diagram ...............................EL-219 Audio and A/C control removal and installation - See Instrument panel .............BT-15 Auto air conditioner - Wiring diagram ............HA-42 Automatic amplifier .........................................HA-87 Automatic transaxle number............................GI-44 Automatic transmission fluid replacement..........................................MA-49, 50 Auxiliary air control (AAC) valve ..............................EC-QG-274, EC-SR-263

Back door opener - See Back door ............BT-9, 11 Back door trim.................................................BT-30 Back door window ....................................BT-35, 56 Back-up lamp ................................................EL-107 BACK/L - Wiring diagram..............................EL-107 Ball joint front axle ....................................FA-32, 33 Base idle air volume initialiging...........................EC-QG-33, EC-SR-46 Basic inspection ....................EC-QG-72, EC-SR-84 Battery .............................................................EL-29 Body alignment ...............................................BT-60 Brake booster .................................................BR-18 Brake control valve (Proportioning valve)...........................................................BR-11 Brake fluid change ...........................................BR-7 Brake fluid level .............................................MA-51 Brake fluid level and line check .......................BR-7 Brake hydraulic line ..........................................BR-9 Brake inspection ............................................MA-51 Brake lining wear temporary checking ..........MA-51 Brake pedal ....................................................BR-13 Bulb specifications ........................................EL-137 Bumper, front ....................................................BT-5 Bumper, rear .......................................BT-5, 7, 9, 11 BUZZER - Wiring diagram ............................EL-181 C Camshaft inspection ...............EM-35, 91, 138, 147, 183, 192, 196 Camshaft position sensor (CMPS)..........................EC-QG-238, EC-SR-239 Camshaft position sensor (PHASE) ......EC-QG-238 Canister-See EVAP canister ..............................EC-QG-25, EC-SR-27 CHARGE - Wiring diagram .............................EL-53 Charging system .............................................EL-53 Chassis and body maintenance ....................MA-48 CHIME - Wiring diagram...............................EL-181 Cigarette lighter.............................................EL-203 Circuit breaker.................................................EL-22 CKPS - Wiring diagram....EC-QG-234, EC-SR-236, 292, EC-CD-115 Clock .............................................................EL-203 Closed throttle position switch ...............EC-SR-271 Clutch cover ....................................................CL-13 Clutch damper ................................................CL-10 Clutch disc ......................................................CL-13 Clutch fluid level.............................................MA-48 Clutch master cylinder ......................................CL-8 Clutch operating cylinder ..................................CL-9 Clutch release mechanism..............................CL-11 CMPS - Wiring diagram ....EC-QG-240, EC-SR-242 Coil spring (rear).............................................RA-11 Collision diagnosis..........................................RS-57 Combination meter........................................EL-138

IDX-2

ALPHABETICAL INDEX Combination meter removal and installation - See Instrument panel......................BT-15 Combination switch .........................................EL-64 Combustion chamber replacement ..............EM-146 Component location (cool box) ......................HA-39 Compression pressure ..........EM-69, 126, 188, 196 Compressor clutch removal and installation .................................................HA-111 Compressor mounting ..................................HA-109 Compressor precaution ....................................HA-7 Compressor special service tool ......................HA-7 Connecting rod......EM-55, 171, 176, 186, 193, 200 Connecting rod bearing clearance....EM-58, 111, 115, 170, 187, 195, 201 Connecting rod bushing clearance ........EM-59, 116 Console box - See Instrument panel ..............BT-15 CONSULT for ABS .........................................BR-69 CONSULT for engine ...........EC-QG-55, EC-SR-68, EC-CD-27 CONSULT-II general information.....................GI-39 Control sleeve position sensor ................EC-CD-74 Converter housing installation .......................AT-117 COOL/F - Wiring diagram ....................EC-QG-292, EC-SR-282, EC-CD-89 Coolant replacement .........................MA-19, 29, 40 Cooling circuit (engine) ........................LC-8, 21, 31 Cooling fan control ...........EC-QG-289, EC-SR-279, EC-CD-20, 87 Cooling fan motor .............EC-QG-299, EC-SR-289 Cooling fan relay ..............EC-QG-299, EC-SR-289, EC-CD-96 Crank angle sensor built into distributor - See Camshaft position sensor .......EC-QG-238, EC-SR-239 ‘‘Crankcase emission control system See positive crankcase ventilation’’.........................EC-QG-28, EC-SR-30 Crankcase ventilation system - See Positive crankcase ventilation ..........................EC-QG-28, EC-SR-30 Crankshaft ........EM-53, 57, 61, 110, 113, 118, 131, 138, 139, 167, 172, 175, 186, 194, 200 Crankshaft position sensor (OBD) .......EC-QG-232, EC-SR-234, 290 Crankshaft position sensor (POS).........EC-QG-232 Crankshaft position sensor (TDC)..........EC-CD-114 CSPS - Wiring diagram ...........................EC-CD-75 Cylinder block .........................EM-52, 55, 109, 166, 173, 184, 192, 199 Cylinder head ..........EM-31, 86, 140, 178, 188, 196 D Data link connector for Consult ..............................EC-QG-29, EC-SR-31 Daytime light system.......................................EL-78 DEF - Wiring diagram ...................................EL-209 Detonation sensor - See Knock sensor............................EC-QG-228, EC-SR-230 Diagnosis sensor unit .....................................RS-13

Diagnostic trouble code (DTC) for OBD system ...................................EC-QG-6, EC-SR-6 Diagnostic trouble code (DTC) inspection priority chart...............EC-QG-80, EC-SR-92, EC-CD-39 Dimensions ......................................................GI-45 Direct ignition system ..............................EC-QG-32 Door lock .........................................................BT-13 Door mirror ......................................................BT-58 Door trim .........................................................BT-24 Door, front .......................................................BT-13 Door, rear ........................................................BT-13 Drive belt inspection ..........................MA-18, 28, 39 Drive plate runout...................................EM-60, 117 Drive shaft (front) ............................................FA-15 Dropping resistor (A/T)....................................AT-78 DTC work support .................EC-QG-63, EC-SR-76 DTRL - Wiring diagram ...................................EL-79 E ECCS relay ............................................EC-CD-140 ECM input/output signal......EC-QG-91, EC-SR-103 ECTS - Wiring diagram....EC-QG-122, EC-SR-134, EC-CD-67 EGR control (EGRC) - solenoid valve ...EC-CD-129 EGR control valve..........................EC-QG-252, 311 EGR temperature sensor ......................EC-QG-300 EGR/TS - Wiring diagram .....................EC-QG-302 EGRC - Wiring diagram .........................EC-CD-131 EGRC1 - Wiring diagram ..............EC-QG-248, 309 Electric governer ......................................EC-CD-78 Electric sun roof ............................................EL-230 Electrical diagnoses.........................................GI-24 Electrical ignition system.......EC-QG-23, EC-SR-25 Electrical unit ................................................Foldout Electronic fuel injection pump ..................EC-CD-24 Engine control circuit diagram ...........EC-QG-17, EC-SR-19, EC-CD-11 Engine control component parts location ..............................EC-QG-14, EC-SR-15 Engine control module (ECM) .....EC-QG-282, EC-SR-277, EC-CD-9, 86 Engine control system diagram and chart................EC-QG-18, EC-SR-20, EC-CD-12 Engine coolant temperature sensor (ECTS)........EC-QG-120, EC-SR-132, EC-CD-66 Engine fail-safe system.........EC-QG-81, EC-SR-93 Engine oil filter replacement ....................MA-24, 45 Engine oil precautions .......................................GI-6 Engine oil replacement ......................MA-24, 34, 45 Engine removal..............................EM-48, 106, 162 Engine serial number ......................................GI-44 Engine trouble diagnoses ........................EC-CD-33 EVAP canister .......................EC-QG-26, EC-SR-28 EVAP canister purge volume control solenoid valve ...........EC-QG-26, 262, EC-SR-28 EVAP canister purge volume control valve ..............................EC-QG-262, EC-SR-250 EVAP vapor lines inspection....................MA-26, 37

IDX-3

ALPHABETICAL INDEX Evaporative emission (EVAP) system ...............................EC-QG-25, EC-SR-27 Exhaust gas recirculation (EGR) valve...........................................EC-QG-244, 305 Exhaust system ................................................FE-9 Exhaust system inspection ............................MA-48 Exterior ............................................................BT-31 F FCUT - Wiring diagram..........................EC-CD-101 F/FOG - Wiring diagram................................EL-110 Final drive (FF M/T) ...........................MT-32, 51, 71 Floor trim .........................................................BT-18 Fluid temperature sensor (A/T) .......................AT-94 Fluids..............................................................MA-16 Flywheel (clutch) .............................................CL-14 Flywheel runout..............................EM-60, 117, 177 Fog lamp, front ..............................................EL-110 Fog lamp, rear...............................................EL-112 F/PUMP - Wiring diagram..........................EC-QG-338, EC-SR-317 Freeze frame data ................EC-QG-38, EC-SR-50 Fresh vent door control linkage adjustment ..................................................HA-83 FRO2 - Wiring diagram ........EC-QG-135, 154, 162, EC-SR-147, 165, 172 FRO2/H - Wiring diagram..........................EC-QG-168, EC-SR-177 Front axle ..........................................................FA-9 Front bumper ....................................................BT-5 Front disc brake .............................................BR-23 Front door .......................................................BT-13 Front fog lamp .......................................EL-110, 111 Front fog lamp removal and installation ...........BT-5 Front heated oxygen sensor (HO2S)......................................EC-QG-132, 139, EC-SR-144, 150, 156, 162, 170 Front heated oxygen sensor (HO2S) heater ............................EC-QG-166, EC-SR-175 Front passenger air bag .................................RS-17 Front seat ........................................................BT-40 Front seat belt ..................................................RS-3 Front suspension ............................................FA-26 Front washer .................................................EL-186 Front wiper ....................................................EL-186 FTS - Wiring diagram ............................EC-CD-105 FUEL - Wiring diagram .........EC-QG-210, 217, EC-SR-213, 220 Fuel cut control (at no load & high engine speed)....................EC-QG-25, EC-SR-27 Fuel cut solenoid valve ..........................EC-CD-100 Fuel filter ...............................EC-QG-29, EC-SR-31 Fuel filter replacement .......................MA-23, 33, 43 Fuel gauge ............................................EL-141, 146 Fuel injection system....................EC-QG-208, 215, EC-SR-212, 218, EC-CD-15, 18 Fuel injector ......................EC-QG-318, EC-SR-302 Fuel line inspection............................MA-22, 33, 43

Fuel precautions ................................................GI-7 Fuel pressure check .............EC-QG-29, EC-SR-31 Fuel pressure regulator.........EC-QG-30, EC-SR-32 Fuel pressure release ...........EC-QG-29, EC-SR-31 Fuel pump .........................EC-QG-336, EC-SR-316 Fuel pump and gauge ......................................FE-7 Fuel pump relay ................EC-QG-336, EC-SR-316 Fuel system ......................................................FE-6 Fuel tank vacuum relief valve ..................................EC-QG-26, EC-SR-28 Fuel temperature sensor .................EC-CD-17, 104 Fuse ..................................................EL-22, Foldout Fuse block ....................................................Foldout Fusible link ........................................EL-22, Foldout G Garage jack and safety stand .........................GI-47 Gauges..........................................................EL-138 Gear components (M/T) ...........................MT-16, 49 Generic scan tool (GST) .......EC-QG-66, EC-SR-78 GLOW - Wiring diagram ........................EC-CD-120 Glow plug .........................................EC-CD-15, 118 Glow relay ................................................EC-CD-15 GOVNR - Wiring diagram ........................EC-CD-79 Grille - See Exterior ........................................BT-38 Ground distribution..........................................EL-23 H H/AIM - Wiring diagram ....................EL-87, 93, 200 Harness connector ............................................EL-6 Harness layout ..............................................EL-368 Hazard warning lamp ....................................EL-117 Headlamp..................................................EL-67, 69 Headlamp aiming control ................................EL-87 Headlamp washer .........................................EL-200 Headlining - See Roof trim .............................BT-25 Heated oxygen sensor (HO2S) (front) ........................................EC-QG-132, 139, EC-SR-144, 150, 156, 162, 170 Heated oxygen sensor (HO2S) heater (front) .............................EC-QG-166, EC-SR-175 Heated oxygen sensor (HO2S) heater (rear)..............................EC-QG-203, EC-SR-207 Heated oxygen sensor (rear) ...............EC-QG-171, EC-SR-180, 187, 194, 201 Heated oxygen sensor inspection ...........MA-27, 38 Heated seat .......................................BT-42, EL-234 HEATER - Wiring diagram .............................HA-40 HFC134a (R134a) system service procedure..................................................HA-100 HFC134a (R134a) system service tools ..........HA-8 H/LAMP - Wiring diagram ...............................EL-67 Hood..................................................................BT-5 Horn ..............................................................EL-203 HORN - Wiring diagram................................EL-203

IDX-4

ALPHABETICAL INDEX How to erase DTC for OBD system ...............................EC-QG-44, EC-SR-56 HSEAT - Wiring diagram...............................EL-234 Hydraulic lash adjuster inspection .........EM-96, 189

Lubrication circuit (engine) ...................LC-4, 15, 26 Lubrication-locks, hinges and hood latches ........................................................MA-54 Luggage compartment trim .............................BT-29 Luggage room lamp ......................................EL-131

I M IACV-AAC valve ................EC-QG-274, EC-SR-263 IATS - Wiring diagram.......EC-QG-117, EC-SR-128 Identification plate............................................GI-44 Idle air control (IAC) system ...........................EC-QG-274, EC-SR-263 Idle air control valve (IACV)............................EC-QG-274, EC-SR-263 Idle mixture ratio ...................EC-QG-32, EC-SR-34 Idle speed .............................EC-QG-32, EC-SR-34 IGN/SG - Wiring diagram .......................EC-SR-308 Ignition coil .............................................EC-SR-310 Ignition control system ......EC-QG-323, EC-SR-306 Ignition timing ........................EC-QG-32, EC-SR-34 Ignition wire inspection ..............MA-36, EC-SR-229 ILL - Wiring diagram .....................................EL-125 Illumination ....................................................EL-124 INJECT - Wiring diagram..EC-QG-319, EC-SR-303 Injection nozzle inspection .............................MA-46 Injection timing control valve ...................EC-CD-82 Injector ...................................................EC-QG-318 Injector removal and installation..........................EC-QG-30, EC-SR-32 Input shaft (FF M/T) .................................MT-21, 58 Instrument panel .............................................BT-15 INT/L - Wiring diagram..................................EL-132 Intake air temparature sensor ............................EC-QG-116, EC-SR-127 Intake door control linkage adjustment ..........HA-83 Intake door motor .....................................HA-81, 83 Intake valve timing control solenoid valve...................................................EC-QG-284 Interior .............................................................BT-18 Interior lamp ..........................................EL-124, 130

MAFS - Wiring diagram .......EC-QG-112, EC-SR-122, EC-CD-63 MAIN - Wiring diagram .......EC-QG-103, EC-SR-115, EC-CD-59 Mainshaft (M/T) ........................................MT-24, 63 Malfunction indicator lamp (MIL) ..................................EC-QG-45, EC-SR-58 Manual transmission number ..........................GI-44 Manual transmission oil replacement ......MA-48, 49 Mass air flow sensor (MAFS)........EC-QG-110, EC-SR-120, EC-CD-62 METER - Wiring diagram .....................EL-141, 146 MIL & Data link connectors circuit .............................EC-QG-354, EC-SR-329 MIL/DL - Wiring diagram.....EC-QG-354, EC-SR-329, EC-CD-142 MIRROR - Wiring diagram............................EL-231 Mirror defogger .............................................EL-207 Mirror, door......................................................BT-58 Mirror, out side ................................................BT-58 Misfire................................EC-QG-222, EC-SR-224 Mode door control linkage adjustment ...........HA-82 Model variation ................................................GI-41 Molding - See Exterior ....................................BT-31 M/T major overhaul ..................................MT-14, 47 M/T removal and installation ..........................MT-10 Mud guard - See Exterior ...............................BT-37 MULTI - Wiring diagram................................EL-298 Multi-remote control system..........................EL-296 Multiport fuel injection (MFI) system ...............................EC-QG-21, EC-SR-23 Multiport fuel injection precautions ....................GI-6

K

N

Knock sensor (KS) .......................EC-QG-228, 229, EC-SR-230, 231 KS - Wiring diagram ..............................EC-QG-229

NATS (Nissan anti-theft system)...................EL-342 NATS (Nissan anti-theft system) precautions ..............................................GI-3, 25 NATS - Wiring diagram .................................EL-343 Needle lift sensor .....................................EC-CD-97 Neutral position switch ......EC-QG-313, EC-SR-298 NLS - Wiring diagram ..............................EC-CD-98 NVH troubleshooting (BR)................................BR-6 NVH troubleshooting (CL) ................................CL-3 NVH troubleshooting (EM)...............EM-11, 64, 121 NVH troubleshooting (M/T) ..............................MT-7 NVH troubleshooting (RA)................................RA-3

L License lamp .................................................EL-100 Lifting points ....................................................GI-46 Line pressure solenoid valve ..........................AT-74 Line pressure test (A/T) ..................................AT-35 Liquid gasket application .................................EM-5 LOAD - Wiring diagram .........................EC-QG-352 Location of electrical units ............................EL-365 Lubricants.......................................................MA-16

IDX-5

ALPHABETICAL INDEX O Oil cooler (engine) ....................................LC-20, 30 Oil pan (engine) ...............................EM-17, 70, 129 Oil pressure (engine)............................LC-5, 16, 27 Oil pump (engine).................................LC-5, 17, 27 Oil pump regulator valve (engine) ....................LC-7 Oil seal replacement (engine)................................EM-29, 84, 138, 139 On board diagnostic system ...............................EC-QG-36, EC-SR-48 Operational check (cool box) .........................HA-24 P Park/Neutral position switch.............................EC-QG-313, EC-SR-298 Park/neutral position switch (A/T) ...................AT-48 Parking brake control .....................................BR-48 Parking lamp .................................................EL-100 PCV (positive crankcase ventilation) .........................EC-QG-28, EC-SR-30 PCV system inspection............................MA-26, 36 Periodic maintenance (for Europe) ..................MA-6 PGC/V - Wiring diagram ...EC-QG-264, EC-SR-252 PHASE - Wiring diagram.......................EC-QG-240 Pilot bushing replacement - See Pilot converter...................................................EM-117 Piston assembly..............EM-53, 60, 110, 117, 167, 175, 176, 185, 193, 199 Piston pin inspection.............EM-54, 110, 168, 171, 185, 193, 199 Piston ring inspection....................EM-54, 111, 168, 185, 193, 199 Piston to bore clearance........................EM-56, 174 PNP/SW - Wiring diagram..........................EC-QG-315, EC-SR-300 POWER - Wiring diagram...............................EL-12 Power door lock ....................................EL-245, 265 Power door mirror .........................................EL-231 Power seat ....................................................EL-233 Power steering fluid level...............................MA-53 Power steering oil pressure switch.............................EC-QG-342, EC-SR-321 Power supply routing ......................................EL-10 Power transistor......................................EC-SR-311 Power transistor & ignition coil ..............EC-SR-306 Power window ...............................................EL-236 Pre-delivery inspection.....................................MA-4 Precautions (General) .......................................GI-4 Pressure test (A/T) ..........................................AT-35 PST/SW - Wiring diagram..........................EC-QG-343, EC-SR-322 R Radiator ..........................................LC-9, 13, 25, 36

Rear axle (disc brake type) ..............................RA-5 Rear bumper ...........................................BT-7, 9, 11 Rear combination lamp removal and installation ...................................................BT-37 Rear disc brake ........................................BR-33, 40 Rear door ........................................................BT-14 Rear drum brake ............................................BR-44 Rear fog lamp................................................EL-112 Rear heated oxygen sensor (HO2S)..EC-QG-171, EC-SR-180, 187, 194, 201 Rear heated oxygen sensor (HO2S) heater ............................EC-QG-203, EC-SR-207 Rear seat ........................................................BT-43 Rear seat belt ...................................................RS-4 Rear suspension ..............................................RA-4 Rear washer..................................................EL-193 Rear window ...................................................BT-53 Rear window defogger ..................................EL-207 Rear wiper.....................................................EL-193 Refrigerant connection precaution ...................HA-4 Refrigerant general precaution.........................HA-4 Refrigerant lines ...........................................HA-104 Refrigerant pressure sensor....................EC-QG-299, 347, EC-SR-289 Refrigeration cycle..........................................HA-12 Removal and installation (A/T) ......................AT-116 Revolution sensor (A/T) ............................AT-61, 65 R/FOG - Wiring diagram ...............................EL-112 Roof trim .........................................................BT-25 RRO2 - Wiring diagram.....................EC-QG-174, 183, 191, 199, EC-SR-183, 190, 197, 203 RRO2/H - Wiring diagram..........................EC-QG-205, EC-SR-209 S SAE J1930 terminology list .............................GI-51 Seal - See Exterior .........................................BT-31 SEAT - Wiring diagram .................................EL-233 Seat belt inspection .......................................MA-54 Seat belt pre-tensioner ...................................RS-13 Seat belt pre-tensioner disposal ....................RS-27 Seat, front .......................................................BT-40 Self-diagnostic results ...........EC-QG-46, EC-SR-59 Shift control components (M/T) .........MT-17, 50, 74 Shock absorber (rear).....................................RA-11 Side air bag ....................................................RS-19 Side trim ..........................................................BT-18 Side window - See Rear side window ............BT-55 S/LOCK - Wiring diagram .....................EL-248, 270 Spark plug replacement...........................MA-25, 35 Speedometer ........................................EL-141, 146 Spiral cable.....................................................RS-14 Spot lamp..............................................EL-130, 131 SROOF - Wiring diagram .............................EL-230 SRS - See Supplemental Restraint System ..........................................................RS-8 SRS - Wiring diagram ....................................RS-33

IDX-6

ALPHABETICAL INDEX S/SIG - Wiring diagram....EC-QG-333, EC-SR-313, EC-CD-145 Stabilizer bar (front) ........................................FA-32 Stall test (A/T) .................................................AT-34 Standardized relay ............................................EL-8 START - Wiring diagram .................................EL-37 Start signal .................EC-QG-38, 332, EC-SR-312, EC-CD-145 Starter .......................................................EL-37, 43 Starting system ...............................................EL-37 Steering gear and linkage inspection ............MA-53 Steering knuckle........................................FA-11, 12 Stop lamp ......................................................EL-104 STOP/L - Wiring diagram..............................EL-104 Sun roof, electric ...........................................EL-230 Sunload sensor ..............................................HA-86 Sunroof .....................................................BT-31, 46 Super lock .............................................EL-245, 265 Supplemental Restraint System .......................RS-8 Supplemental restraint system - Wiring diagram .......................................................RS-33 Symbols and abbreviations .............................GI-38 Symptom matrix chart ...........EC-QG-82, EC-SR-94 Synchronizer (M/T) ......................MT-22, 27, 59, 65 System readiness test (SRT) code ..........EC-SR-50 T Tachometer ...........................................EL-141, 146 Tail lamp ........................................................EL-100 TCM circuit diagram ........................................AT-10 TCM inspection table ......................................AT-41 Temperature control cable and linkage adjustment ..................................................HA-83 THEFT - Wiring diagram...............................EL-316 Theft warning system ....................................EL-311 Thermal protector .........................................HA-113 Thermo control amp .......................................HA-80 Thermostat..........................................LC-11, 23, 34 Third link (front susp.) .....................................FA-29 Three way catalyst ............EC-QG-258, EC-SR-246 Three way catalyst precautions.........................GI-6 Throttle position sensor (TPS) .............................EC-QG-125, EC-SR-137 Throttle position sensor adjustment .........................EC-QG-72, EC-SR-84 Throttle position switch ...............EC-SR-271, AT-85 Tightening torque of standard bolts.................GI-50 Time control system......................................EL-306 Timing belt....................................................EM-131 Timing chain.............................................EM-19, 75 Tire rotation ....................................................MA-53 Tire size ...........................................................GI-45 Torque converter installation .........................AT-117 Torque convertor clutch solenoid valve...........AT-69 Tow truck towing ..............................................GI-46 Towing point.....................................................GI-49 TP/SW - Wiring diagram ........................EC-SR-273 TPS - Wiring diagram .......EC-QG-128, EC-SR-140 Transmission case (M/T)................................MT-39

Transverse link (front) .....................................FA-32 Trim .................................................................BT-18 Triple pressure switch ....................................HA-79 Trouble diagnoses ...........................................GI-35 Trunk lid ............................................................BT-7 Trunk lid opener - See Trunk lid .......................BT-7 Trunk room lamp...................................EL-130, 131 Trunk room trim...............................................BT-28 Turbocharger........................................EM-156, 201 Turbocharger precautions..................................GI-6 TURN - Wiring diagram.................................EL-118 Turn signal lamp............................................EL-117 Two trip detection logic .........EC-QG-36, EC-SR-48 U Upper link (front susp.) ...................................FA-29 V Vacuum hose (brake system).........................BR-20 Vacuum hose drawing (Engine control)............EC-QG-19, EC-SR-21, EC-CD-13 Valve clearance .............................EM-40, 179, 191 Valve guide..............EM-36, 93, 142, 180, 189, 197 Valve lifter ..............................EM-40, 145, 179, 198 Valve seat................EM-38, 95, 143, 182, 190, 198 Valve spring.............EM-39, 96, 145, 179, 189, 197 Vehicle identification number...........................GI-43 Vehicle speed sensor (VSS) ..........EC-QG-267, EC-SR-255, EC-CD-70 Viscosity number (SAE) .................................MA-17 VSS - Wiring diagram.......EC-QG-269, EC-SR-257, EC-CD-71 W WARN - Wiring diagram ...............................EL-167 Warning buzzer .............................................EL-180 Warning chime ..............................................EL-180 Warning lamps ..............................................EL-165 Washer, front.................................................EL-186 Washer, rear..................................................EL-193 Water cock control rod adjustment ................HA-82 Water pump ........................................LC-10, 22, 33 Water temperature gauge.....................EL-141, 146 Weatherstrip - See Exterior ............................BT-31 Wheel alignment (front) ..................................FA-35 Wheel alignment (rear).....................................RA-6 Wheel balance ...............................................MA-53 Wheel bearing (front axle) ....................FA-6, 12, 35 Wheel bearing (rear) ........................................RA-5 Wheel hub (front) ............................................FA-12 Wheel hub (rear) ..............................................RA-7 Wheel sensors (ABS) .....................................BR-53 Wheel size .......................................................GI-45 Wheelbase (Dimensions) ................................GI-45

IDX-7

ALPHABETICAL INDEX Wide open & closed throttle position switch.............................EC-QG-125, EC-SR-137 Width (Dimensions) .........................................GI-45 WINDOW - Wiring diagram ..........................EL-240 Windshield.......................................................BT-53 WIP/R - Wiring diagram ................................EL-195

Wiper and washer .........................................EL-188 Wiper, front....................................................EL-186 Wiper, rear ....................................................EL-193 Wiring diagrams ...............................................GI-11

IDX-8

FUSE BLOCK — Junction Box (J/B) Terminal Arrangement To time control unit

UP

Fuel pump relay Spare fuse

Front fog lamp relay Power window relay Rear window defogger relay To room lamp harness :

To air bag harness

To main harness: To main harness

Ignition relay

To engine room harness

Circuit breaker-1

Blower relay

: LHD models : RHD models To body harness

YEL232C

FUSE AND FUSIBLE LINK BOX Terminal Arrangement

With gasoline engine With diesel engine

YEL419B

ELECTRICAL UNITS Terminal Arrangement

TCM (Transmission control module)

TCM (Transmission control module)

ABS CONTROL UNIT

ECM (SR engine and QG engine)

ECM (CD engine)

YEL233C

NOTES

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